Production and Properties of Soft Magnetic Cores Made From Fe-Rich FeSiBPCu Powders

Abstract

Fe-rich Fe 83.3 Si 4 B 8 P 4 Cu 0.7 powders with the particle sizes below 150 μm were prepared by spinning water atomization process. As-prepared powders were structurally amorphous. The powders with small and large particle size were insulated with the phenol resin and compacted to a toroidal shaped core (outer diameter ∼13, inner diameter ∼8, and height ∼5-6 mm) by cold-pressing at the pressure of ∼0.5-1.5 GPa. Core loss decreases, and magnetic permeability increases after annealing treatment at 350°C for 20 min. The powder particles in the annealed core consist of nanocrystalline α-Fe grains in the amorphous matrix. Cores exhibit a constant initial permeability (μ i ) up to the frequency range of ∼30 MHz. Core loss is shown to be dependent on particle size. Cores made from smaller powder particles have low core loss at high frequencies. Our powder cores exhibit lower core loss than the Somaloy500 powder cores measured under the magnetic induction of 0.5 T, and are promising for filling the gaps in high frequency and high induction application of ferrite materials.Index Terms-Core loss, nanocrystalline, powder core (PC), soft magnetic property, spinning water atomization process (SWAP). 0018-9464

Vector Hysteresis Processes for Innovative Fe-Si Magnetic Powder Cores: Experiments and Neural Network Modeling

“…On the one hand, iron-based alloys available in form of laminations still constitute a suitable solution for the manufacturing of electrical machines and magnetic components in the industrial and energy environment [1,2]. However, to meet the requirements of power consumption for high-frequency applications, and the need of either reducing the size and the weight of the cores or creating complex geometries, other technologies have been proposed and explored, such as ferrites [3][4][5], soft magnetic composites (SMC) [6], and more recently additive-manufactured cores [7,8] and magnetic powder cores [9][10][11]. In particular, the latter one is attracting a lot of interest since it matches good magnetic properties with high workability and suitable mechanical and thermal properties.…”

Properties of Fe-based nanocrystalline magnetic powder cores (MPC) and structure of particle size distribution (PSD)

“…Due to stable permeability and low power loss at a high frequency bandwidth, MPCs are used in power circuits [14,15], switching power supplies [15,16], filter inductors and smoothing chokes [17], radio and communication devices [15], coupling devices [18] or electrical motors and generators [17,19], diesel fuel injection valves or reactors in boost converters for hybrid cars [17] and many others.…”