MSc Thesis Work for: CFD Simulation of Resin Impregnation in Electric Machine Insulation System

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This Position reports to:

Details:

• Period: Start Jan-June 2027
• 30 ECTS per student
• Number of students: 1
• Location: ABB Corporate Research in Västerås, Sweden

You will be part of Materials Technology & Electromagnetics team at ABB Corporate Research in Västerås, Sweden. At Corporate Research we lead the innovation within ABB and our task is to ensure ABB's technology competitiveness now and in the future. We work in close collaboration with other research centers, our business areas: Motion, Automation and Electrification, as well academic and industrial partners. In our creative and highly skilled team we develop, design, build and test new concepts and prototypes of physical and digital powertrains or electrical devices.

Vacuum Pressure Impregnation (VPI) is a critical manufacturing process used to ensure the reliability and lifetime of high-voltage electric machines. During the VPI process, resin penetrates complex mica-based insulation systems, filling voids and improving the mechanical and electrical integrity of the insulation. However, the layered structure of mica tapes can create anisotropic impregnation behavior and preferential flow paths, making resin infiltration difficult to predict.

This thesis aims to improve the understanding of resin impregnation mechanisms within electric machine insulation systems using Computational Fluid Dynamics (CFD) simulations. The work will focus on investigating resin flow behavior, flow anisotropy, and interactions between resin and insulation structures. The outcome is expected to support improved impregnation quality, reduced void formation, and more robust insulation system designs.

Your responsibilities

• Conduct a literature review on resin impregnation, porous media flow, and electric machine insulation systems.
• Develop CFD models to simulate resin impregnation during the VPI process.
• Investigate the influence of insulation architecture and material properties on resin flow behavior.
• Analyze flow anisotropy, preferential flow paths, and potential void formation mechanisms.
• Identify key parameters affecting impregnation quality and propose recommendations for improved insulation design and processing.

Qualifications for the role

• Master of Science student in Mechanical Engineering, Engineering Physics, Material Sciences, Electrical Engineering, or a related field.
• Good knowledge of fluid mechanics and transport phenomena.
• Good knowledge of CFD and numerical simulations.
• Interest in porous media flow and composite materials.
• Experience with simulation tools such as ANSYS Fluent, COMSOL, OpenFOAM, or similar are beneficial.

More about us

Recruiting Manager  David Lindell , 46 72 461 35 03, will answer your questions.

Main contacts :  Göran Paulsson, goran.paulsson@se.abb.com; Binaya Baidar, binaya.baidar@se.abb.com;

Positions are filled continuously. Please apply with your CV, academic transcripts, and a cover letter in English.

We look forward to receiving your application!

A future opportunity

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