Amorphous Magnetic Core Research Articles

Preparation of low-loss amorphous soft magnetic powder cores by joint coating of resin and ZnO nanoparticles

Preparation of low-loss amorphous soft magnetic powder cores by joint coating of resin and ZnO nanoparticles

Co-hydrolysis of TEOS and DDS to obtain a modified hydrophobic SiO2 insulation layer for FeSiBC amorphous magnetic powder core with low energy loss

The hysteresis effect and eddy currents caused by alternating magnetic fields greatly impede the improvement of the working efficiency and performance stability of soft magnetic powder cores. In this work, modified hydrophobic SiO2 nanoparticles were prepared by tetraethyl orthosilicate (TEOS) and dimethyl-diethoxy-silane (DDS) as co-precursors through sol–gel methods. The effect of different proportions of DDS and TEOS on the amorphous magnetic powder cores performance was studied. It was demonstrated that the insulation layer in DDS and TEOS co-precursors hydrolyzed composite powders exhibited more uniform distribution compared with TEOS hydrolyzed alone counterpart. The introduction of methyl groups reduced the accumulation of hydrolysis intermediates on the surface of FeSiBC powders. Furthermore, the addition of DDS reduced eddy current loss significantly with a low hysteresis loss. The total energy loss of the DDS and TEOS co-hydrolysis powder core were reduced by 16.1 % and 7.7 % at 1 MHz, 0.05 T compared to the uncoated powder core and the TEOS hydrolysis alone counterpart, respectively. The presented results provide insights into improving the application range and energy utilization efficiency for the magnetic powder cores.

Fabrication of FeSiBCr/wollastonite amorphous soft magnetic powder cores with low loss and high-quality factor

In this paper, the best magnetic properties of FeSiBCr/wollastonite soft magnetic composites were explored by adjusting the content of wollastonite powder and annea- ling temperature. FeSiBCr/wollastonite soft magnetic composites with low loss and high quality factor were successfully prepared by adding micron-sized wollastonite po-wder into amorphous magnetic powder. Wollastonite was used as the insulating coating material of amorphous magnetic powder for the first time, which showed good performance in reducing the loss of magnetic powder. The loss change of FeSiBCr/wollastonite magnetic powder cores was studied by B-H analyzer and loss separation analysis model. The results show that the total loss (Pcv) of FeSiBCr/woll- astonite composite cores is lower than that of the pure FeSiBCr cores. With the incre- ase of wollastonite powder content and annealing temperature, the total loss of FeSiBCr/wollastonite composite powder cores shows a trend of first decreasing and then increasing. The composite powder cores containing 0.8 wt% wollastonite powder was heat treated at 678 K for 1 hour under the protection of nitrogen, and its magnetic properties were the best, with a permeability of 28.93 and a loss of 196.2 mW/cm3( f =1 MHz and Bm =20 mT). Wollastonite is a new coating material, which has a good effect of reducing loss. At the same time, this work also provides a new scheme for reducing the total loss of soft magnetic powder cores.

Study on the Magnetic Property of Fe-Si-B Amorphous Magnetic Powder Core Mixed with Carbonyl Iron

Study on the Magnetic Property of Fe-Si-B Amorphous Magnetic Powder Core Mixed with Carbonyl Iron

Evaluation of Rotational Speed Limits in an Axial Flux-Switching Motor Constructed from Metal Amorphous Nanocomposite Magnetic Cores

Evaluation of Rotational Speed Limits in an Axial Flux-Switching Motor Constructed from Metal Amorphous Nanocomposite Magnetic Cores

Development of a high-sensitivity orthogonal fluxgate sensor

Fluxgate magnetometers are one of the most common magnetometers to use as they offer a reliable solution for magnetic anomaly detection. These magnetometers are used in room temperature, exhibiting high sensitivity, making them ideal for several applications. In this paper, a new fluxgate magnetometer design is presented, that is based on a sinusoidal signal for the excitation of the magnetic core and offers improved sensitivity and low power consumption. The developed device is able to operate as a standalone fluxgate sensor based on the orthogonal topology, consisting of one sensing coil, an amorphous magnetic wire core, as well as a microcontroller along with the required electronics for its operation and signal process.

High Temperature Superconducting Transformer Operating at an Increased Frequency of Alternating Current

The study's aim is to substantiate and employ materials with high technical characteristics for the active elements of a transformer, particularly in the context of increased operating frequencies. To accomplish this objective, the following tasks were addressed: An analysis and synthesis of the properties of a magnetic core composed of amorphous iron and superconducting windings in a high-temperature superconducting transformer (HST) were conducted. Dependencies and graphs illustrating the impact of frequency increase on heat losses related to hysteresis and eddy currents were derived. These losses occur within the magnetic circuit. The study also demonstrates the relationship between reducing size and weight parameters and material consumption of windings in high-temperature superconducting (HST) tapes. Current densities in these tapes can reach up to 500 A/mm². The most noteworthy outcome, taking advantage of superconductivity in the HST, is that HST acts as an ideal diamagnetic material. Additionally, the windings exhibit high electrical conductivity. This resolves issues related to current displacement to the conductor's surface, commonly known as the "skin effect," and effectively addresses concerns about increased resistance in transformers and electrical machines. The absence of the skin effect in HST conductors has been rigorously demonstrated using Bessel functions. The significance of these results is in enhancing the efficiency of transformers operating at high frequencies. This is achieved by synthesizing the properties of the transformer's active elements, which include an amorphous iron magnetic core, HST windings, and a dielectric medium utilizing liquid nitrogen.

Magnetic properties of phosphoric acid passivated Fe-Si-B amorphous magnetic powder core

The magnetic properties of Fe-Si-B amorphous soft magnetic powder cores (SMCs) passivated by phosphoricacid are investigated in this work. Effects of phosphoric acid content and annealing temperature at different frequencies on permeability and magnetic loss of SMCs have been studied, too. Electronic microscope pictures and results of B-H analyzer show that the surface of Fe-Si-B SMCs is coated with a layer of dense phosphate. Experimental results show that Fe-Si-B SMCs with the best comprehensive magnetic properties (μe = 23.71; Pcv = 470.6 mW•cm−3 measured at 1000 kHz, 20 mT) can be obtained by adding 0.8 wt% phosphoric acid at the annealing temperature of 480 °C.

Effect of annealing process on magnetic properties of Fe80Co3Si3B10P1C3 amorphous alloy magnetic cores

Effect of annealing process on magnetic properties of Fe80Co3Si3B10P1C3 amorphous alloy magnetic cores

Study on the magnetic property of Fe–Si–B amorphous magnetic powder core coated with Al2O3/phosphoric acid–Al2O3 double layer

Study on the magnetic property of Fe–Si–B amorphous magnetic powder core coated with Al2O3/phosphoric acid–Al2O3 double layer

Industrial-scale fabrication of amorphous magnetic powder cores with excellent high-frequency magnetic properties: Optimization for kinds and content of insulating agents

Based on the powder metallurgy method, FeBSiC amorphous powders were produced by a novel gas-water combined atomization process and were co-coated by five kinds of insulating agents (polyamide, aluminum dihydrogen phosphate, calcium phosphate, zinc phosphate and hydrochloric acid) and epoxy resins. The content of each insulating agents was optimized to improve the magnetic properties of the amorphous magnetic powder cores (AMPCs). The results showed that the FeBSiC powders showed extremely high saturation magnetization (171.1 emu·g–1) and low coercivity (6.11 Oe), which could provide excellent raw materials for AMPCs. Among the five insulating agents, the polyamide-coated AMPCs had the worst electrical insulating effect and magnetic properties. Although the AMPCs coated with aluminum dihydrogen, zinc phosphate, calcium phosphate and hydrochloric acid all exhibited low eddy current losses, only the AMPCs coated with calcium phosphate exhibited extremely low hysteresis losses. As the calcium phosphate content increased, the density and resistance of the AMPCs both increased and then decreased, and the core losses decreased and then increased. When the calcium phosphate content was 0.5 wt.%, the FeBSiC@ calcium phosphate + epoxy resins core-shell structured AMPCs had high permeability of 28.1 ± 0.3, high DC bias% of 96.1 ± 0.2 at a DC magnetic field of 5671.5 A·m–1, and low core loss of 18.0 ± 0.8 kW·m–3 at 100 kHz and 0.02 T, which showed excellent magnetic properties at high frequency and confirmed to the current development trend of miniaturization, high-frequency and high-efficiency in electrical and electronic fields.

Microstructure evolution and soft magnetic property optimization of core-shell FeSiBCCr@SiO2&ZrO2 amorphous magnetic powder cores

In this study, core-shell structured FeSiBCCr@SiO2&ZrO2 amorphous magnetic powder cores (AMPCs) were successfully prepared by the sol-gel method using tetraethyl orthosilicate (TEOS) and zirconium oxychloride hydrate (ZrOCl2·8H2O) as raw materials. The growth mechanism and potential chemical reactions of the SiO2&ZrO2 mixed insulation layer were analyzed by XRD, XPS and SEM‒EDS. In addition, the effect of the insulation layer content on the soft magnetic properties of FeSiBCCr@SiO2&ZrO2 AMPCs was systematically investigated. The SiO2&ZrO2 insulation layer can significantly increase the resistivity, effectively improve the DC bias performance and reduce the core loss of AMPCs. S2* (1.2 mL TEOS and 1.4 g ZrOCl2·8H2O) had a minimum core loss of 2290 mW/cm3 at high frequency (50 mT, 1 MHz). It had a high effective permeability of 48.2 and a superior direct current (DC) bias performance of 77.9% at 8 kA/m. This study provides a valid method to practically produce SMPCs with high resistivity, low core loss at high frequency and excellent DC bias performance through a novel insulation coating process.

Fe-Based Amorphous Magnetic Powder Cores with Low Core Loss Fabricated by Novel Gas-Water Combined Atomization Powders.

FeSiBCCr amorphous powders were produced by a novel gas–water combined atomization process, and the corresponding MPCs (magnetic powder cores) were subsequently fabricated by phosphating treatment (0.4~1.6 wt.%), cold pressing (550~2350 MPa), and annealing (423~773 K), respectively. The results showed that the powders had high circularity, excellent thermal stability (ΔT = 59 K), and high saturation magnetization (0.83 T), which could provide raw powders for high-performance MPCs. With increasing phosphoric acid concentrations, despite the increase in DC-bias%, the uniformity of the insulation layers deteriorated, which led to a decrease in permeability and an increase in core loss. With increasing compaction pressures, the core loss increased continuously, and the permeability and DC-bias% first increased and then decreased. When annealing below the crystallization temperature, with increasing annealing temperatures, the permeability increased, and the core loss and DC-bias% decreased continuously. Under the optimized process of 0.4 wt.% phosphating concentration, 550 MPa pressure, and 773 K annealing temperature, the MPCs had a permeability of 21.54 ± 1.21, DC-bias% of 90.3 ± 0.2, and a core loss (Bm = 50 mT, f = 100 kHz) of 103.0 ± 26.3 mW cm−3. The MPCs had excellent high-frequency low-loss characteristics and showed great application potential under the development trends of high current, high power, and high frequency of electronic components.

Hybrid Microfluxgate and Current Transformer Sensor

In this work, we develop the hybrid current sensor comprising a microfluxgate and a current transformer (CT) for wide-bandwidth current measurement. The microfluxgate consists of two microcoil chips 3.5 mm <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"> <tex-math notation="LaTeX">$\times1.75$ </tex-math></inline-formula> mm in dimension made by using the standard Complementary Metal-Oxide Semiconductor MicroElectroMechanical Systems (CMOS-MEMS) <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"> <tex-math notation="LaTeX">$0.35 ~\mu \text{m}$ </tex-math></inline-formula> process. The aluminum wire-bonding technique is used to construct the top excitation coil surrounding the amorphous soft magnetic core patterned by photolithography and wet etching techniques. Under the optimal excitation condition, the response of the microfluxgate current sensor becomes linear with a maximized sensitivity. The in-house made CT is combined with the microfluxgate driving system to form the hybrid current sensor by using a summing amplifier. The hybrid current sensor has a spectral current noise of 0.4 mA/ <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"> <tex-math notation="LaTeX">$\surd $ </tex-math></inline-formula> Hz at 1 Hz. The maximum sensing range is ±10 A, and the non-linearity is less than 2% within the ±4.6 A range, corresponding to a linear dynamic range of 60 dB in a 10 Hz bandwidth. The hybrid microfluxgate-and-CT sensor has a flat bandwidth from dc to 100 kHz. It has the potential to become a practical miniature device featuring a high-dynamic range, wide bandwidth, and low-temperature drift.

Enhanced high frequency properties of FeSiBPC amorphous soft magnetic powder cores with novel insulating layer

Fe-based amorphous magnetic powder cores (AMPCs) with excellent comprehensive properties were successfully fabricated via using the uniform double insulating layer core-shell structured FeSiBPC/Fe3O4@Epoxy resin (EP). The effects of the in-situ hydrothermal oxidized time on the magnetic properties of the AMPCs have been systematically investigated on the basis of the growth mechanism of the insulating layer of spherical amorphous powder in alkaline environment. The hydrothermal oxidation process could well ensure the uniformity of the oxide layer composed of Fe3O4 nanoparticle. The evolution of the insulating layer is a process of homogeneous nucleation and growth at different hydrothermal oxidation time. After 10 h of hydrothermal oxidation, a thin and dense layer composed of Fe3O4 nanoparticle was formed on the surface of the amorphous powder. As a consequent, the FeSiBPC AMPCs exhibit excellent performance such as stable effective permeability of 49.5 at 2 MHz, a very low core loss of 187 mW/cm3 at 100 kHz@0.05 T and high-quality factor of 160 at 600 kHz. The results indicate that the thickness of the Fe3O4 insulating layer can be completely controlled via the reaction parameters, and can effectively suppress the eddy current loss, which is promising for high-frequency electromagnetic systems.

The Influence of Thermomagnetic Treatment of Cores of Amorphous Magnetic Materials on the Metrological Characteristics of Electromagnetic Transformers of Current

We consider a method of thermomagnetic treatment of amorphous magnetic material cores in a transverse constant magnetic field designed to improve the metrological characteristics of current transformers. The effectiveness of the method is due to a significant increase in the magnetic permeability of the cores of current transformers. The use of thermomagnetic processing makes it possible to increase their precision class.

The Influence of External Operating Conditions on the Generator with Amorphous Low-Coercivity Magnetic Core

The Influence of External Operating Conditions on the Generator with Amorphous Low-Coercivity Magnetic Core

Fabrication and Characterization of a Flexible Fluxgate Sensor with Pad-Printed Solenoid Coils.

This paper presents the fabrication and characterization of a flexible, flat, miniaturized fluxgate sensor with a thin amorphous rectangular magnetic core fabricated by the pad/printing technique. Both the design and the various printing steps of the sensor are presented. The fluxgate sensor comprises of solenoid coils, and to the best of our knowledge, is the first to be printed with a conventional micro-printing technique. The magnetic core is a non-printed component, placed between the printed layers. The sensor’s linear measuring range is ±40 µT with 2% full-scale linearity error, at 100 kHz excitation frequency. The highest measured sensitivity reaches 14,620 V/T at 200 kHz, while the noise of the sensor was found to be 10 nT/ at 1 Hz.

Study of a 18-Pulse Transformer–Rectifier Unit with an Amorphous Steel Magnetic Core

This article discusses a study of transformer–rectifier units with a magnetic core made of amorphous steel. Transformers with various types of amorphous alloys have been analyzed, and the optimum amorphous alloy for transformers was determined. Thermal processes in transformers with magnetic core of amorphous steel have been simulated, and the maximum temperature under normal operating conditions has been determined. The simulation has demonstrated that no special transformer cooling system is required. An experimental transformer–rectifier unit has been designed and manufactured with a magnetic core of amorphous steel installed on an 18-pulse rectifier with a capacity of 10.5 kV A operating with a frequency of 400–800 Hz and voltage of 115/27 V. To verify the obtained data, experimental studies have been performed that confirmed the validity of the selected design procedure of a transformer engineering flowchart. It has been demonstrated that the thermal loads detected in the transformer during testing are in the range of allowable values.

Enhancements of preparation efficiency and magnetic properties for Fe-based amorphous magnetic flake powder cores upon the adoption of a novel double-paralleled slits nozzle

The thick and brittle amorphous ribbons with the maximum thickness up to 58 μm were successfully fabricated using melt-spinning method upon the adoption of a novel double-paralleled slits nozzle (DPSN). The magnetic properties of the two magnetic flake powder cores (MFPCs) prepared from the conventional thin ribbon pulverization and the thick ribbon pulverization were analyzed and compared. Hereinto, a coupling model of fluid flow with free surface and surface tension, and heat transfer with phase transform was developed to design the slit spacing for the DPSN, and sol-gel method was employed to create SiO2 insulation layer on the surfaces of the magnetic flake powders to improve electrical resistivity. Results show that a quasi-steady-state can be reached for the puddle with the upstream and downstream menisci in crescent and slope shapes, respectively, by adopting the DPSN with slit spaces of 2.0 mm and 2.5 mm. The embrittlement process for the conventional thin ribbon can be omitted to enhance the efficiency of the powder preparation when using the thick ribbon before the ribbon pulverization. The MFPCs fabricated using the thick amorphous ribbon pulverization exhibit a higher permeability of 65.27, lower total core loss with the frequency being less than 234 kHz for Bm = 0.08 T, and a better DC-bias property of 70.97% as compared to the MFPCs made from the conventional thin amorphous ribbon pulverization. This work provides a promising approach to further development of Fe-based amorphous MFPCs with high preparation efficiency and excellent magnetic properties at the frequency below 234 kHz.