Iron Powder + Epoxy Armature for Generator

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Discussion Overview

The discussion revolves around the feasibility and effectiveness of using a mixture of iron powder and epoxy to create an armature for a generator. Participants explore the magnetic properties and construction techniques relevant to generator design.

Discussion Character

  • Technical explanation, Conceptual clarification, Debate/contested

Main Points Raised

  • One participant inquires about the effectiveness of mixing iron powder and epoxy for generator armatures.
  • Another participant suggests that high permeability is crucial for the magnetic circuit, noting that the typical permeability of iron powder and epoxy is around 100 to 150, compared to steel laminations which are approximately 4000.
  • A participant questions the term "steel laminations" and seeks clarification on its meaning.
  • A later reply explains that steel laminations are thin layers (~0.4 mm thick) used in generator and alternator armatures to minimize AC eddy currents, except in certain types of rotors.

Areas of Agreement / Disagreement

Participants express differing levels of understanding regarding the materials and concepts involved, with some seeking clarification while others provide technical insights. No consensus is reached on the effectiveness of the iron powder and epoxy mixture.

Contextual Notes

The discussion highlights the importance of magnetic permeability in generator design and the potential limitations of using iron powder and epoxy compared to traditional materials like steel laminations. Specific assumptions about material properties and their implications for performance remain unexamined.

R3KR
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Any have good results by mixing iron powder and epoxy, purpose is to create an armature for a generator.
 
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I think you want high permeability of the magnetic circuit including both armature and stator. Typical permeability (I think) of iron powder and epoxy is ~ 100 or 150, while steel laminations are ~ 4000. In rotating machinery, one of the limitations is the low permeability of the gap (=1) between armature and stator.
Bob S
 
Thanks for your answer.

Steel Laminations ?
What is that ?
 
R3KR said:
Thanks for your answer.

Steel Laminations ?
What is that ?
Most generator and alternator armatures (except permanent magnet rotors on brushless dynamos) have steel laminations ~ 0.4 mm thick in the armature to reduce ac eddy currents in the steel.
Bob S
 

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