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Sustainable manufacturing of Fe-Co electric steel sheets via additive screen printing.

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Title: Sustainable manufacturing of Fe-Co electric steel sheets via additive screen printing.
Authors: Lindemann, Inge1 (AUTHOR) inge.lindemann-geipel@ifam-dd.fraunhofer.de, Anbudass, Joshua J.1 (AUTHOR), Reuter, Kay1 (AUTHOR), Thamm, Merlin1 (AUTHOR), Weise, Bruno1 (AUTHOR), Studnitzky, Thomas1 (AUTHOR), Weißgärber, Thomas1,2 (AUTHOR)
Source: Metallurgical Research & Technology. 2025, Vol. 122 Issue 6, p1-12. 12p.
Subjects: Iron-cobalt alloys, Screen process printing, Waste minimization, Magnetic properties, Economic efficiency, Electric machinery, Sustainability
Abstract: Electric drives designed for high-performance applications with extreme power density often rely on Fe49Co2V electrical steel sheets instead of Fe-Si, as this alloy offers exceptionally high magnetic induction along with high magnetic permeability. Conventionally, these motor sheets are fabricated using milling, followed by the final shaping through punching or laser cutting. However, due to the high cost of cobalt and the complexity of mechanical processing, components made from this material are extremely expensive. Given that cobalt is a critical raw material, increasing its utilization efficiency is of significant economic and strategic interest. In this context, additive screen printing presents a sustainable and near-net shape manufacturing route for producing stator and rotor geometries from Fe-Co alloys. This technique significantly enhances material yield, particularly of cobalt, by minimizing waste typically generated during subtractive methods. Furthermore, by using elementary powder mixtures instead of gas-atomized pre-alloyed powders, the material costs can be substantially reduced. This not only enables tailored alloying during processing, but also broadens accessibility for scalable production. The study compares the magnetic properties achieved through both conventional and additive manufacturing approaches. It demonstrates that screen printing of Fe-Co electric steels can achieve competitive performance, offering a cost-effective and resource-efficient alternative for producing high-performance motor components. [ABSTRACT FROM AUTHOR]
Copyright of Metallurgical Research & Technology is the property of EDP Sciences and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Sustainable manufacturing of Fe-Co electric steel sheets via additive screen printing.
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  Data: <searchLink fieldCode="AR" term="%22Lindemann%2C+Inge%22">Lindemann, Inge</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> inge.lindemann-geipel@ifam-dd.fraunhofer.de</i><br /><searchLink fieldCode="AR" term="%22Anbudass%2C+Joshua+J%2E%22">Anbudass, Joshua J.</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Reuter%2C+Kay%22">Reuter, Kay</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Thamm%2C+Merlin%22">Thamm, Merlin</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Weise%2C+Bruno%22">Weise, Bruno</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Studnitzky%2C+Thomas%22">Studnitzky, Thomas</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Weißgärber%2C+Thomas%22">Weißgärber, Thomas</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Metallurgical+Research+%26+Technology%22">Metallurgical Research & Technology</searchLink>. 2025, Vol. 122 Issue 6, p1-12. 12p.
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  Data: <searchLink fieldCode="DE" term="%22Iron-cobalt+alloys%22">Iron-cobalt alloys</searchLink><br /><searchLink fieldCode="DE" term="%22Screen+process+printing%22">Screen process printing</searchLink><br /><searchLink fieldCode="DE" term="%22Waste+minimization%22">Waste minimization</searchLink><br /><searchLink fieldCode="DE" term="%22Magnetic+properties%22">Magnetic properties</searchLink><br /><searchLink fieldCode="DE" term="%22Economic+efficiency%22">Economic efficiency</searchLink><br /><searchLink fieldCode="DE" term="%22Electric+machinery%22">Electric machinery</searchLink><br /><searchLink fieldCode="DE" term="%22Sustainability%22">Sustainability</searchLink>
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  Data: Electric drives designed for high-performance applications with extreme power density often rely on Fe49Co2V electrical steel sheets instead of Fe-Si, as this alloy offers exceptionally high magnetic induction along with high magnetic permeability. Conventionally, these motor sheets are fabricated using milling, followed by the final shaping through punching or laser cutting. However, due to the high cost of cobalt and the complexity of mechanical processing, components made from this material are extremely expensive. Given that cobalt is a critical raw material, increasing its utilization efficiency is of significant economic and strategic interest. In this context, additive screen printing presents a sustainable and near-net shape manufacturing route for producing stator and rotor geometries from Fe-Co alloys. This technique significantly enhances material yield, particularly of cobalt, by minimizing waste typically generated during subtractive methods. Furthermore, by using elementary powder mixtures instead of gas-atomized pre-alloyed powders, the material costs can be substantially reduced. This not only enables tailored alloying during processing, but also broadens accessibility for scalable production. The study compares the magnetic properties achieved through both conventional and additive manufacturing approaches. It demonstrates that screen printing of Fe-Co electric steels can achieve competitive performance, offering a cost-effective and resource-efficient alternative for producing high-performance motor components. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Metallurgical Research & Technology is the property of EDP Sciences and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1051/metal/2025087
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        Text: English
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      – SubjectFull: Screen process printing
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      – SubjectFull: Waste minimization
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      – SubjectFull: Electric machinery
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      – TitleFull: Sustainable manufacturing of Fe-Co electric steel sheets via additive screen printing.
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              M: 11
              Text: 2025
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