Abstract
Efficient and cost-effective soft magnetic materials (SMMs) are essential for accelerating the adoption of electric vehicles and the sustainable growth of renewable electricity. While amorphous and nanocrystalline SMMs offer remarkably low magnetic losses, their poor mechanical properties, limited availability in size and shape (particularly ribbon widths), and high cost prevent them from widespread industrial application. Here, we show that ductile Fe-6.5%Si 2-D flakes could be used as building blocks for making high performance bulk SMMs. This approach bypasses the brittleness problem and creates a new morphology and a new fabrication method for the SMMs with improved energy efficiency and lower processing cost. Ductile Fe-6.5%Si flakes are mass-produced by melt spinning and are then consolidated to bulk SMMs with a brick-wall type of structure. The novel process introduces anisotropic electrical and magnetic properties and enables near net shape processing. Resulting Fe-6.5%Si thin sheets display low iron loss (W10/400 = 6.1 W/kg) and high permeability (µr = 28,000), which are comparable to the current state of the art high silicon steel. CaF2 coating reduces the iron losses for thick Fe-6.5%Si parts. Polymer coated Fe-6.5%Si flake cores show potential for high power inductors with greater permeability and lower losses than traditional powder cores.
Highlights
Intensive competition for lower capital and ownership cost demands electric machines and power electronics with higher power density and efficiency
Resulting Fe-6.5%Si thin sheets display low iron loss (W10/400 = 6.1 W/kg) and high permeability, which are comparable to the current state of the art high silicon steel
Coercivity is sensitive to the magnetocrystalline anisotropy energy (MAE), which is an intrinsic property determined by the crystal structure and how it is coupled to the magnetization
Summary
Intensive competition for lower capital and ownership cost demands electric machines and power electronics with higher power density and efficiency. Operation at a higher frequency has adverse impacts on a system’s efficiency due to increasing magnetic losses, which include hysteresis loss (Wh) and eddy current loss (We). SMMs should have high permeability so that a high magnetic flux can be achieved with less current and low coercivity so that less magnetic energy is wasted on demagnetizing the magnet. It should have high saturation magnetization (Ms) for realizing higher energy density. Low magnetostriction is essential for reduced operation noise and contributes to high permeability
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