Abstract
We report on new high-saturation induction, high-temperature nanocomposite alloys with reduced glass formers. The amounts of the magnetic transition metals and early transition metal growth inhibitors were systematically varied to determine trade-offs between higher inductions and fine microstructures with consequently lower magnetic losses. Alloys of nominal composition (Fe65Co35)79.5+xNb4−xB13Si2Cu1.5 (x=0–4) were cast into a 28 mm wide, 20 μm thick ribbon from which toroidal cores were wound. Inductions and magnetic losses were measured after nanocrystallization and stress relief. We report technical magnetic properties: permeability, maximum induction, remanence ratio, coercive field, and high frequency magnetic losses as a function of composition and annealing temperature for these alloys. Of note is the development of maximum inductions in excess of 1.76 T in cores made of alloys with the x=4 composition and maximum inductions in excess of 1.67 T in alloys with the x=3 composition, which also exhibit power losses smaller than 10 W/kg at 0.2 T induction levels in 20 kHz fields. We discuss optimization of induction with chemistry and correlate the microstructures with losses.
Highlights
The need for magnetic materials in vehicle electrical power systems is motivated by a desire to replace transformers and other power electronic components with those that can operate at higher power densities, at higher frequencies and temperatures in extreme environments
This requires soft magnetic materials that operate at high temperatures with high inductions and low losses
Nanocomposites have ultrafine nanocrystalline grains, often nucleating on Cu clusters, homogeneously dispersed in an amorphous matrix that is enriched in metalloid glass formers and early transition metal growth inhibitors
Summary
The need for magnetic materials in vehicle electrical power systems is motivated by a desire to replace transformers and other power electronic components with those that can operate at higher power densities, at higher frequencies and temperatures in extreme environments. This requires soft magnetic materials that operate at high temperatures with high inductions and low losses. The need for magnetic materials in vehicle electrical power systems is motivated by a desire to replace transformers and other power electronic components with those that can operate at higher power densities, at higher frequencies and temperatures in extreme environments.. The need for magnetic materials in vehicle electrical power systems is motivated by a desire to replace transformers and other power electronic components with those that can operate at higher power densities, at higher frequencies and temperatures in extreme environments.1 This requires soft magnetic materials that operate at high temperatures with high inductions and low losses. Nanocrystalline soft magnetic alloys based on the FeCo system called HITPERM have been reported for high-temperature application.3,4 Work on these alloys has concentrated on materials with Fe:Co ratios of 50:50 ͑Ref. 3͒ where low magnetocrystalline anisotropy is observed in bulk alloys; 65:35– 70:30 ͑Ref. 5͒ near the peak in the Slater–Pauling curve; and less than 10:90 ͑Refs. This work is aimed at investigating further development of materials with the largest inductions
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