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This paper presents detailed steps and procedures for the design of a 4-pole, 0.75-hp, 1500-r.p.m. surface-mounted permanent magnet brush-less DC (SPM-BLDC) motor. The motor has been fabricated at the works of a local manufacturer. The parameters of the machine have been analytically evaluated and subsequently compared to the experimentally determined values. Its practical performance on load has been experimentally evaluated in the laboratory and verified against analytical predictions too. Low-cost M45 electrical steel laminations, as used for commercial induction motors (IMs), have been used from considerations of cost and availability. This also enables direct comparison of important parameters (e.g. torque density, power density and efficiency) between the fabricated prototype and commercially available fractional-hp 3-phase and 1-phase IMs of similar rating. This study is significant since electrical motor manufacturers need not change their stator stamping production line for BLDC motor vis-a-vis IM in case of mass production. Such an approach is hardly reported in the available technical literature. Analytical methods adopted include both conventional hand calculations and finite-element analysis using commercially available software package(s). Excellent agreements between analytical and experimental values uphold the correctness of the design process, precision of fabrication and accuracy of experimental investigations.

This paper presents a novel and exhaustive investigation involving in-depth analysis, performance evaluation and comparative study of two 0.75 hp, 4-pole, 1500 rpm laboratory prototypes of Brushless DC (BLDC) motors of identical nominal ratings with surface and interior permanent magnet rotor structures having the same stator and winding (integral slot distributed winding). Both the motors were designed and developed in the lab. The major electrical variables (such as rated power, speed, voltage, current, number of poles, etc.) and the stator (such as core material, stator lamination, stack length, winding pattern and wire gauge) of the fabricated prototypes have also been kept identical to pin-point the direct influence of the two different rotor configurations (viz., surface vs interior permanent magnet) on the parameters, performance and operation of these BLDC motors. Additionally, to ensure unbiased basis for appropriate comparison, the overall volumes of magnets/pole in both the motors have also been kept similar. A detailed comparison of different quantities like air-gap flux density distribution, THD in induced voltage, torque ripple, losses and efficiency, torque–speed characteristics with field-weakening capability, steady state parameters at different operating conditions, etc. has been conducted for the said motors and the salient points duly highlighted. The vulnerability of the permanent magnets to demagnetisation based on armature reaction, particularly during a sudden fault, has also been investigated in both the cases. The theoretically determined parameters and analytically evaluated performance figures have been verified through standard FEM packages, and later validated experimentally on the fabricated prototypes. Very good mutual agreement has been observed between predicted and experimental values.

Bulk magnetic materials with the noncentrosymmetric cubic B20 structure are fascinating due to skyrmion spin structures associated with Dzyaloshinskii–Moriya interactions, but the size of skyrmions are generally larger than 50 nm. The control of such spin structures in the 10 nm size ranges is essential to explore them for spintronics, ultra-high-density magnetic recording, and other applications. In this study, we have fabricated MnSi nanoparticles with average sizes of 9.7, 13.1 and 17.7 nm and investigated their structural and magnetic properties. X-ray diffraction and transmission electron microscope studies show that the MnSi nanoparticles crystallize in the cubic B20 structure. Field-dependent dc susceptibility data of the MnSi samples with average particle sizes of 17.7 and 13.1 nm show anomalies in limited field (about 25–400 Oe) and temperature (25 K–43 K) ranges. These features are similar to the signature of the skyrmion-like spin structures observed below the Curie temperature of MnSi. Our results also show that this anomalous behavior is size-dependent and suppressed in the smallest nanoparticles (9.7 nm), and this suppression is interpreted as a confinement effect that leads to a truncation of the skyrmion structure.

Amorphous Fe32Ni52Zr3B13, prepared by rapid solidification, undergoes crystallization during high-energy mechanical milling. The resulting structure consists of face-centered cubic (fcc) FeNi and Zr3Ni20B6 nanocrystallites. Structural evolution and defect analysis of as-solidified Fe32Ni52Zr3B13 ribbons with different milling times is investigated. From the differential thermal analysis (DTA) curve of amorphous ribbons, exothermic peaks were observed at 415 °C and 475 °C corresponding to the crystallization of fcc Zr3Ni20B6 phase and fcc FeNi phase, respectively. However, high-energy mechanical milling induces the formation of FeNi within the first 2 h of mechanical milling. Further milling induces the crystallization of Zr3Ni20B6. Doppler broadening positron annihilation spectroscopy (DBPAS) was used to investigate vacancy-type defects. The milling-induced crystallization appears to be related to enhanced vacancy-type defect concentrations allowing growth of pre-existing Fe(Ni) nuclei. The milling and enhanced vacancy concentration also de-stabilizes the glass, leading to decreased crystallization temperatures for both phases, and ultimately eliminating the glass transition altogether.

Mn-based silicides are fascinating due to their exotic spin textures and unique crystal structures, but the low magnetic ordering temperatures and/or small magnetic moments of bulk alloys are major impediments to their use in practical applications. In sharp contrast to bulk Mn5Si3, which is paramagnetic at room temperature and exhibits low-temperature antiferromagnetic ordering, we show ferromagnetic ordering in Mn5Si3 nanoparticles with a high Curie temperature (Tc ≈ 590 K). The Mn5Si3 nanoparticles have an average size of 8.6 nm and also exhibit large saturation magnetic polarizations (Js = 10.1 kG at 300 K and 12.4 kG at 3 K) and appreciable magnetocrystalline anisotropy constants (K1 = 6.2 Mergs/cm(3) at 300 K and at 12.8 Mergs/cm(3) at 3 K). The drastic change of the magnetic ordering and properties in the nanoparticles are attributed to low-dimensional and quantum-confinement effects, evident from first-principle density-functional-theory calculations.

High-anisotropy arc-melted and field-annealed Mn100−x Bi x (x = 50–65) alloys have been investigated. Samples predominantly consist of low-temperature phase (LTP) MnBi and elemental Bi, where the LTP volume fraction and sample magnetization decrease with increasing x. All samples are hard ferromagnetic at room temperature and demonstrate a structural and magnetic phase transition at 630 K. For Mn35Bi65, the highest values for coercivity (4.6 kOe), magnetization remanence ratio (0.97), and energy product (4.9 MGOe) are measured at 540 K, near the melting point of bismuth. We explain the trend in magnetic properties as a consequence of c-axis alignment of MnBi grains facilitated by the molten Bi during magnetic field annealing.

We report the fabrication of a rare-earth-free permanent-magnet material Co3Si in the form of nanoparticles and investigate its magnetic properties by experiments and density-functional theory (DFT). The DFT calculations show that bulk Co3Si has an easy-plane anisotropy with a high K1 ≈ −64 Merg/cm3 (−6.4 MJ/m3) and magnetic polarization of 9.2 kG (0.92 T). In spite of having a negative anisotropy that generally leads to negligibly low coercivities in bulk crystals, Co3Si nanoparticles exhibit high coercivities (17.4 kOe at 10 K and 4.3 kOe at 300 K). This result is a consequence of the unique nanostructure made possible by an effective easy-axis alignment in the cluster-deposition method and explained using micromagnetic analysis as a nanoscale phenomenon involving quantum-mechanical exchange interactions.