Compaction of SMC Materials by Applying External Magnetic Fields to the Mold

The interest about the adoption of Soft Magnetic Composites (SMC) in substitution of the traditional laminated steels is increasing. The adoption of this innovative materials makes possible to move from 2d- to 3d-design concept for what concerns the realization of the magnetic circuits of electrical machines. The past activity of the authors in the development of new SMC materials has brought to experience new process solutions, particularly during molding process. In the present paper the impact of a magnetic field the application, directly inside the mold, in the same instant of the compacting pressure is evaluated. The research has been approached by experiments on ‘ad hoc’ magnetic samples self-produced by the authors. Different measurement techniques are proposed, passing from traditional magnetic tests to innovative thermographic methods and microscope analysis. Interesting results are obtained in terms of magnetic performances, both from the magnetization and iron losses point of view. An axial flux machine prototype has been realized, and the significant results of the experimental tests allowed to obtain an energetic characterization which confirms the interesting conclusions of the study.