In-Situ Coating of High-Silicon Electrical Steel using Laser Powder Bed Fusion

In-Situ Coating of High-Silicon Electrical Steel using Laser Powder Bed Fusion | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article In-Situ Coating of High-Silicon Electrical Steel using Laser Powder Bed Fusion Babak Haghighat, Mohammad Mokhles, Marta Roldo, Soran Birosca This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6753890/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 26 Aug, 2025 Read the published version in Progress in Additive Manufacturing → Version 1 posted You are reading this latest preprint version Abstract Theorists, experimentalists, and industrialists have all acknowledged that further improvements of electrical steel (ES) magnetic properties using the current chemical composition (< 3.2 wt% Si) and conventional manufacturing routes remains extremely challenging. However, to enable the prevailing vehicle and aircraft electrifications revolution, further developments in materials and electrical machine designs are required. Today, additive manufacturing (AM) unlocks opportunities to produce steels with high Si content (> 6.5 wt% Si) which are otherwise unprocessed through conventional thermomechanical route due to the brittle nature of high-silicon alloys. However, challenges around their inferior magnetic properties remain to be overcome. Here, a novel in-situ coating, i.e., lamination during 3D printing of 6.5%Si steel is demonstrated. The in-situ steel lamination via “Successive Building and Coating” approach was conducted through a combination of powder coating and printing strategies that enabled a production of a near net shape laminated high Si electrical steel. The Ar atomised 6.5 wt% Si steel powder was coated with (Mn,Zn) ferrite via sol-gel auto-combustion method and with SiO2 via sol-gel method for comparison purposes. The coated powder was fused in the ProX300 Laser Powder Bed Fusion to build successive and insulated layer-by-layer structure of high Si steel parts. The in-situ lamination was successfully achieved; however, the coating layers were non-uniform and occasionally discontinuous. It was concluded that the distance between the coating layers varies and cannot be correlated to powder thickness layer. It is demonstrated that a higher powder layer thickness (L) results in a thicker and non-uniform insulating coat layer during in-situ lamination; therefore, a smaller L was recommended. Furthermore, the successive layer-by-layer formation of matrix-coat perpendicular to building direction indicated that Buoyancy effect was affected by other factors that directly influence the-2-metallic-ceramic melt pool dynamics. Finally, it is demonstrated that ferrimagnetic (Mn0.8,Zn0.2)Fe2O4 laminated samples possess superior magnetic properties compared to amorphous SiO2 laminated samples. Electrical Steel Additive Manufacturing In-Situ Lamination Magnetic Property Full Text Additional Declarations Table 1 to 5 are available in the Supplementary Files section. Supplementary Files TablesandAppendix.pdf Cite Share Download PDF Status: Published Journal Publication published 26 Aug, 2025 Read the published version in Progress in Additive Manufacturing → Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6753890","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":465364046,"identity":"6bb5e432-6af9-48e8-92a2-9397ec1ee477","order_by":0,"name":"Babak Haghighat","email":"","orcid":"","institution":"University of Portsmouth","correspondingAuthor":false,"prefix":"","firstName":"Babak","middleName":"","lastName":"Haghighat","suffix":""},{"id":465364047,"identity":"dabbf644-0422-435b-9189-bcb4314c3bed","order_by":1,"name":"Mohammad Mokhles","email":"","orcid":"","institution":"University of Portsmouth","correspondingAuthor":false,"prefix":"","firstName":"Mohammad","middleName":"","lastName":"Mokhles","suffix":""},{"id":465364048,"identity":"74346717-f05a-4944-9b8f-75f71d34f81f","order_by":2,"name":"Marta Roldo","email":"","orcid":"","institution":"University of Portsmouth","correspondingAuthor":false,"prefix":"","firstName":"Marta","middleName":"","lastName":"Roldo","suffix":""},{"id":465364049,"identity":"ad1128f1-83bc-41ac-b199-a5a85878b246","order_by":3,"name":"Soran Birosca","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA+UlEQVRIiWNgGAWjYPCCAzwQugIhZECkljNAzEakFgjF2EaEFvn23oefCxjuyJi3tz/88HPeHTnz+Q2MH34wHDbGpcXgzHFj6RkMz3hkzpwxluzd9sxY5hgDs2QPw2EznFok0hikeRgO80hI5LAx8G47nDgD6DBpBobDNjgdNiON+TdES/ozxr9zwFqYf+PTwnAjjQ1qS4IZM28DWAsbyBbcDjtzjM2ax+AZjwTPGWNpmWPPjCXYEtssewzScXpfvr2N+TZPxR17Cfb2hx/f1NyRk2A+fPjGjwprwwacLgPbBWcdAGLGBsIRiQQOEK90FIyCUTAKRgwAANMOTFnBsyUiAAAAAElFTkSuQmCC","orcid":"","institution":"University of Portsmouth","correspondingAuthor":true,"prefix":"","firstName":"Soran","middleName":"","lastName":"Birosca","suffix":""}],"badges":[],"createdAt":"2025-05-26 22:38:07","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-6753890/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-6753890/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1007/s40964-025-01292-1","type":"published","date":"2025-08-26T15:57:43+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":90345028,"identity":"517be7ea-ba69-4ef1-8220-23a4e7d925a8","added_by":"auto","created_at":"2025-09-01 16:09:34","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":3131210,"visible":true,"origin":"","legend":"","description":"","filename":"PAMManuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-6753890/v1_covered_fe5ae5f6-1f55-426c-a344-fac47a519966.pdf"},{"id":83876788,"identity":"7a40d909-0899-4e61-b5f5-dc424492493d","added_by":"auto","created_at":"2025-06-04 03:46:09","extension":"pdf","order_by":2,"title":"","display":"","copyAsset":false,"role":"supplement","size":2085552,"visible":true,"origin":"","legend":"","description":"","filename":"TablesandAppendix.pdf","url":"https://assets-eu.researchsquare.com/files/rs-6753890/v1/1f92e81e896ce4ac512c8709.pdf"}],"financialInterests":"\u003cp\u003eTable 1 to 5 are available in the Supplementary Files section.\u003c/p\u003e","formattedTitle":"In-Situ Coating of High-Silicon Electrical Steel using Laser Powder Bed Fusion","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Electrical Steel, Additive Manufacturing, In-Situ Lamination, Magnetic Property","lastPublishedDoi":"10.21203/rs.3.rs-6753890/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-6753890/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"Theorists, experimentalists, and industrialists have all acknowledged that further improvements of electrical steel (ES) magnetic properties using the current chemical composition (\u003c 3.2 wt% Si) and conventional manufacturing routes remains extremely challenging. However, to enable the prevailing vehicle and aircraft electrifications revolution, further developments in materials and electrical machine designs are required. Today, additive manufacturing (AM) unlocks opportunities to produce steels with high Si content (\u003e 6.5 wt% Si) which are otherwise unprocessed through conventional thermomechanical route due to the brittle nature of high-silicon alloys. However, challenges around their inferior magnetic properties remain to be overcome. Here, a novel in-situ coating, i.e., lamination during 3D printing of 6.5%Si steel is demonstrated. The in-situ steel lamination via “Successive Building and Coating” approach was conducted through a combination of powder coating and printing strategies that enabled a production of a near net shape laminated high Si electrical steel. The Ar atomised 6.5 wt% Si steel powder was coated with (Mn,Zn) ferrite via sol-gel auto-combustion method and with SiO2 via sol-gel method for comparison purposes. The coated powder was fused in the ProX300 Laser Powder Bed Fusion to build successive and insulated layer-by-layer structure of high Si steel parts. The in-situ lamination was successfully achieved; however, the coating layers were non-uniform and occasionally discontinuous. It was concluded that the distance between the coating layers varies and cannot be correlated to powder thickness layer. It is demonstrated that a higher powder layer thickness (L) results in a thicker and non-uniform insulating coat layer during in-situ lamination; therefore, a smaller L was recommended. Furthermore, the successive layer-by-layer formation of matrix-coat perpendicular to building direction indicated that Buoyancy effect was affected by other factors that directly influence the-2-metallic-ceramic melt pool dynamics. Finally, it is demonstrated that ferrimagnetic (Mn0.8,Zn0.2)Fe2O4 laminated samples possess superior magnetic properties compared to amorphous SiO2 laminated samples.","manuscriptTitle":"In-Situ Coating of High-Silicon Electrical Steel using Laser Powder Bed Fusion","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-06-04 03:46:04","doi":"10.21203/rs.3.rs-6753890/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"cb9687e3-c2f4-412f-8951-6cb10abc9809","owner":[],"postedDate":"June 4th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2025-09-01T16:05:02+00:00","versionOfRecord":{"articleIdentity":"rs-6753890","link":"https://doi.org/10.1007/s40964-025-01292-1","journal":{"identity":"progress-in-additive-manufacturing","isVorOnly":false,"title":"Progress in Additive Manufacturing"},"publishedOn":"2025-08-26 15:57:43","publishedOnDateReadable":"August 26th, 2025"},"versionCreatedAt":"2025-06-04 03:46:04","video":"","vorDoi":"10.1007/s40964-025-01292-1","vorDoiUrl":"https://doi.org/10.1007/s40964-025-01292-1","workflowStages":[]},"version":"v1","identity":"rs-6753890","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-6753890","identity":"rs-6753890","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}