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Given the promising high frequency magnetic properties of metal amorphous nanocomposite (MANC) soft magnetic materials (SMMs), recent efforts seek to use MANCs in electric motors to achieve high specific power utilizing elevated magnetic frequency. Such motors can operate at high rotational speed, as eddy current losses pose less limitations on their performance. It is thus important to understand mechanical stress distributions in a motor constructed from MANCs and to predict the likelihood of failure for such a machine at high speeds. Here, we model the residual stress due to the manufacturing process and the operating rotational stress of a MANC rotor. Previously reported failure distributions of laminated MANC ribbons are then used in conjunction with stress results to predict MANC motor failure rates. Because of brittle MANC failure, a design philosophy based on statistics rather than factor of safety (FOS) is used for a range of rotational speeds in our axial motor design. We estimate the probability of failure in a proof test as a function of operational speed. For our design, we determine that a failure rate of 1 in 10 5 at an operational speed of 12.5 kRPM can be achieved for a 45.8 kW motor.
Schneider et al. (Thu,) studied this question.