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Title:Low temperature manufacturing of ferrite-epoxy inductor cores by micro-robotic deposition
Author(s):Igram, Spencer Scott
Advisor(s):Alleyne, Andrew
Department / Program:Mechanical Sci & Engineering
Discipline:Mechanical Engineering
Degree Granting Institution:University of Illinois at Urbana-Champaign
Additive Manufacturing
Epoxy Composite
Magnetic Core
Material Extrusion
Direct Ink Write
3D printing
Abstract:Inductors and transformers are an important class of passive components in high and pulsed power electronics. Inductive type elements such as these are useful in energy storage, pulse shaping or filtering, and power conversion. These devices are made up of two major components; the conductive windings that provide the inductive properties, and the magnetic cores used to enhance those properties. Power losses associated with these devices can also be categorized by these two components called copper and iron losses, respectively. Iron losses, or core losses, are highly dependent on the materials used and the manufacturing method for the core. Losses come in the form of thermal energy accumulated in the core itself. These devices, which can represent a plurality or even majority composition of power electronics circuitry, pose a significant challenge and opportunity to improve power density capabilities in high and pulsed power electronics. This thesis discusses manufacturing magnetic cores at low temperature (<100 C) and a control method for the manufacturing system. The manufacturing system of interest is micro-Robotic Deposition (uRD), a three-axis material extrusion type additive manufacturing system. The choice of this manufacturing method greatly influences the rheological properties required of the composite inks used for target components. A ferrite-epoxy composite ink consisting of micron-sized carbonyl iron powder and a common industrial epoxy matrix, Bisphenol-A diglycidyl ether (DGEBA)/ Diethylene Triamine (DETA), is used with a rheology modifier to achieve the proper rheology profile of the magnetic ink. A velocity centric PID control strategy is implemented on each axis of the uRD system to achieve proper motion and position control of the manufacturing process. Results show good control performance across printing speeds of 1-25 mm/s, as determined by biaxial contour mappings. Components manufactured from the composite provided hold the desired topology, indicating proper rheological tuning of the ink material, and were fully cured in under 8 hours at ambient room conditions (~23 C).
Issue Date:2018-12-11
Rights Information:Copyright 2018 Spencer Igram
Date Available in IDEALS:2019-02-06
Date Deposited:2018-12

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