State-of-the-Art Assessment of Additive Manufactured Soft Magnetic Material FeSi 2.9 Through Comprehensive Characterization

This work presents a comprehensive experimental characterization of a FeSi 2.9 soft magnetic alloy produced by laser powder bed fusion (L-PBF), aimed at assessing its state-of-the-art and evaluating its suitability for electrical machine cores. Toroidal and bar specimens are fabricated with two build orientations (0° and 90°) and analyzed in both as-built and heat-treated (HT) conditions through microstructural, magnetic, and electrical measurements. The experimentally derived magnetic properties were implemented in a finite-element model (FEM) of a traction motor for a Formula Student racing car. Despite expected limitations, the results demonstrate encouraging performance and highlight the potential of FeSi 2.9 for future additively manufactured cores, provided that further improvements in material formulation, printing process, and loss-mitigation strategies are achieved.