A New Soft Magnetic Composites Material for Electrical Machine: Improvement of Mechanical properties with High Molding Pressure

Several developments concerning the electrical machines have been recently focused: new technologies and materials can improve the efficiency of the machines and of their production processes. With the availability of new magnetic materials, it is now possible to replace ferromagnetic laminated steels with Soft Magnetic Composites (SMC), opening to the possibility to obtain parts having shapes otherwise impossible and with better performances in medium and high frequencies. Some commercial products are available in the market, but with limited mechanical properties for the introduction in electrical machines. The will to improve the mechanical properties still retaining similar magnetic characteristics led the research activity to special iron powders and selected Epoxy and Phenolic resins as binders. The process has been improved investigating different molding pressures and different binder percentages. The results encourage to carry on the research exploring further improvements.