Research projects:
Grand Challenge 1.4

Manufacturing the novel and non-standard materials
Led by University of Strathclyde

For the start of phase 2 of the FEMM hub, a new work stream was launched to focus on novel and nonstandard electrical machine materials. This work package is supported primarily by colleagues in NMIS and AMRC, and is focusing on two key areas: 

1. Materials and manufacturing processes for low temperature operation 

2. Advanced materials and manufacturing technologies for superconducting machines 

Exciting developments over the past few years have included the design of traditional electrical machines for use in cryogenic environments- mainly for use in hydrogen powered aircraft- and the further development of fully superconducting machines. Both technologies are developing rapidly, but the manufacturing technologies that will be required for each- especially when larger volumes will be requiredare still unclear. One of the aims of GC1.4 is to assess the current state-of-the-art in design and material selection for low temperature applications, and link this to the manufacturing research that is already ongoing within the FEMM hub. 

The first key task for this GC is to compare traditional machine topologies with those for low temperature operation, and understanding the crossover potential for standard materials and manufacturing routes. Although a lot of information is known about the performance of standard alloys (such as titanium, aluminium, and steel) at room and elevated temperatures, the mechanical and fatigue properties at cryogenic temperatures are not well understood. GC1.3 previously reviewed the yield stress of key materials in relation to various manufacturing routes (J. Miscandlon et al.: Manufacturing Driven Design Methodology to Lightweighting of the Structural Elements, DOI: 10.1109/ACCESS.2022.3214305), and GC1.4 aims to expand this work by reviewing the academic literature for data on the yield stress below zero degrees. Once this review has been completed and the gaps identified, GC1.4 will be conducting low temperature materials testing within the University of Strathclyde on selected materials, with an aim to publish the results in an academic paper.

GC1.4 is also engaging with the Lightweight Manufacturing Centre (LMC) at NMIS to advance the use of composite materials in future machine design. We are looking at opportunities for the wider use of composites in standard electrical machines for lightweighting purposes, but we are also investigating the performance of such materials in cryogenic environments. Understanding the strengths and limitations of a wide range of materials in temperatures ranging from -220°C to 250°C will be critical in fully optimising the design and manufacture of future machine topologies. 

Once the material properties of metal alloys and composites are understood for low temperature operation, GC1.4 will down-select one or two materials for prototype testing. Working closely with the design team at AMRC and the manufacturing specialists at the LMC and the Advanced Forming Research Centre (AFRC), novel designs will be manufactured and tested for low temperature applications. Throughout the design process, the team will be focused on a range of factors, including material section, design for manufacture, component quality and performance, and sustainability. This integrated product development cycle is shown below. The prototypes that will be produced as part of this GC will also aim to be as lightweight as possible, while building in additional functionality where possible, which links with the aims of GC1.3