General Electric Company

Min Zou

Wanming Zhang

Francis Johnson

Shenyan Huang

Steve John Buresh

Pazhayannur Ramanathan Subramanian

Patel Bhageerath Reddy

James Pellegrino Alexander

Ayman Mohamed Fawzi EL-Refaie

Deborah D Whitis

Lawrence Bernard Kool

Stephen Francis Rutkowski

Changjie Sun

Ananda Barua

Anthony Joseph Vinciquerra

Sudeep Pradhan Sadananda Rao

Raghavendra Rao Adharapurapu

Peter John Bonitatibus, Jr

Vandana Prabhakar Rallabandi

Qi Zhao

Susan Corah

Peter John Bonitatibus

Christopher Jay Klapper

Reshma Saira Mathew

Peter Bonitatibus

Ayman Mohamed Fawzi El-Refaie

Christopher Klapper

A bulk dual phase soft magnetic component having a three-dimensional magnetic flux and its manufacturing methods are described herein. The methods can include combining a first powder material with a second powder material to form a component structure, wherein the first powder material comprises a plurality of first particles each comprising a first core and a reactive coating, and wherein the second powder material comprises a plurality of second particles each comprising a second core and a non-reactive coating, and, consolidating the component structure to join the plurality of first particles with the plurality of second particles.

Bulk dual phase soft magnetic components having three-dimensional magnetic flux and manufacturing methods

Methods for manufacturing dual phase soft magnetic components include combining a plurality of soft ferromagnetic particles with a plurality of paramagnetic particles to form a component structure, wherein the plurality of soft ferromagnetic particles each comprise an electrically insulative coating, and, heat treating the component structure to consolidate the plurality of soft ferromagnetic particles with the plurality of paramagnetic particles.

Dual phase soft magnetic particle combinations, components and manufacturing methods

A dual phase magnetic component, along with methods of its formation, is provided. The dual phase magnetic component may include an intermixed first region and second region formed from a single material, with the first region having a magnetic area and a diffused metal therein, and with the second region having a non-magnetic area. The second region generally has greater than 0.1 weight % of nitrogen.

Dual phase magnetic material component and method of its formation

Methods for forming a dual-phase magnetic component from an initial component comprising a non-magnetic austenite composition are provided. The method may include: forming a coating on a portion of the surface of the initial component to form a masked area while leaving an unmasked area thereon. Thereafter the initial component may be heated to a treatment temperature such that nitrogen diffuses out of the unmasked area of the initial component to transform the non-magnetic austenite composition to a magnetic phase in the unmasked area. Thereafter, the initial component may be cooled from the treatment temperature to form a dual-phase magnetic component having a magnetic region corresponding to the unmasked area and a non-magnetic region corresponding to the masked area.

Fabrication method for a component having magnetic and non-magnetic dual phases

A method of heat-treating an additively-manufactured ferromagnetic component is presented. The additively-manufactured ferromagnetic component includes a metal alloy having iron and cobalt. The method of heat-treating is performed such that a saturation flux density of a heat-treated ferromagnetic component is greater than a saturation flux density of an as-formed ferromagnetic component. The heat-treated ferromagnetic component has a microstructure having an average grain size of substantially all grains in a range of about 0.1 micron to about 25 microns. A ferromagnetic component is also presented.

Method of heat-treating additively-manufactured ferromagnetic components

An AC electric machine that includes a dual magnetic phase material ring is disclosed. The AC electric machine includes a stator assembly and a rotor assembly positioned within the stator assembly and configured to rotate relative thereto, the rotor assembly comprising a rotor core including a stack of rotor laminations that collectively form the rotor core, the rotor core including a plurality of rotor poles separated by gaps therebetween. The AC electric machine also includes a dual magnetic phase material ring positioned about the stack of rotor laminations, the dual magnetic phase material ring comprising a first ring portion comprising a magnetic portion and a second ring portion comprising a non-magnetic portion.

Dual magnetic phase material rings for AC electric machines

A method of forming a component having a variation in saturation magnetization is presented. The method includes selectively diffusing nitrogen into a metallic component of a masked metallic component by exposing the masked metallic component to a nitrogen-rich atmosphere. The masked metallic component includes a patterned oxide layer formed on a surface of the metallic component, and the patterned oxide layer includes an oxide of a metal present in the metallic component. A related component is also presented.

Methods of making a component with variable magnetization and related components

A method includes forming one or more oxide barrier layers on one or more protected portions of a magnetic, metallic body, and converting one or more unprotected portions of the magnetic, metallic body to a less magnetic material by exposing the magnetic metallic body having the one or more oxide barrier layers formed thereon to nitrogen. One or more protected portions of the magnetic, metallic body that are beneath the one or more oxide barrier layers are not converted to the less magnetic material. The method can be used to form one or more layers of a laminated electric motor.

Method for forming a nitrogenation barrier and machine formed using a body having the nitrogenation barrier

A magnetic component including at least one region is disclosed. The at least one region includes nitrogen and a concentration of the nitrogen in the at least one region is graded across a dimension of the at least one region. Further, a saturation magnetization in the at least one region is graded across the dimension of the at least one region. Further, a method of varying the magnetization values in at least one region of the magnetic component is disclosed.

Graded magnetic component and method of forming

A magnetic component including first and second regions, and a method of varying the magnetization values in different regions of the magnetic component are disclosed. The first and the second regions are characterized by a nitrogen content that is different from each other. At least one of the first region and the second region is partially-magnetic and has a nitrogen content in a range from about 0.1 weight % to about 0.4 weight % of that region. A concentration of carbon, if present, of both the first and second regions is less than about 0.05 weight % of the respective regions.

Multi-phase magnetic component and method of forming

A method for selectively removing an aluminum-silicon coating fired on a surface of a metallic structure is described. The method includes the step of contacting the coating with molten potassium hydroxide (KOH), under conditions sufficient to remove the coating without substantially affecting the metallic surface. Methods for preparing a magnetic component are also described. They involve masking pre-selected regions of the surface of the component, using an aluminum-silicon coating that is fired onto the surface, prior to a nitriding step. The coating is then removed according to the procedure outlined herein.

Process for removing aluminum-silicon coatings from metallic structures, and related processes for preparing magnetic components

A shell mold is described. The shell mold includes a facecoat, a sealcoat, and a support disposed in between the facecoat and the sealcoat. The support includes a stucco in a concentration greater than about 40 volume percent of the support. The stucco includes a material that has a thermal conductivity greater than about 285 W/m-K.

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Niskayuna, NY, United States of America

Min Zou