Green Hybrid Manufacturing of 3-Dimensional Fe-6.5%Si Magnetic Cores Integrated with Insulation Layers Via Material Extrusion and Spark Plasma Sintering

초록

A novel hybrid manufacturing approach combining dual-nozzle material extrusion and spark plasma sintering to fabricate metal–insulator–metal (MIM)-structured Fe-6.5 wt% Si (Fe-6.5Si) magnetic cores. Unlike conventional stamping processes, which involve rolling, insulating, punching, and stacking thin Fe-6.5Si sheets, the proposed method simplifies fabrication into fewer steps, eliminates material waste from scrap, and supports a more sustainable manufacturing route. This process integrates MgO-B2O3-SiO2 (MBS) insulation layers to achieve enhanced bonding between the layers. The manufacturing process involved integrating MBS insulation for structural integrity, reducing the Fe-6.5Si layer thickness for frequency stability, and applying a post-heat treatment to improve magnetic performance. The MBS insulation system demonstrated sinterability, forming stable interfaces with the Fe-6.5Si layers. Through experimental investigation, it was found that a Fe-6.5Si layer thickness of 0.6 mm combined with 0.2 mm MBS insulation layers exhibited promising frequency stability up to 1 kHz. Additionally, post-heat treatment at 1200 °C enhances the magnetic properties by increasing the permeability and reducing hysteresis loss through grain growth and interface modification. This hybrid manufacturing approach has the potential to produce high-performance magnetic cores while offering design possibilities for electromagnetic components.

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