Alpha-Fe16 Magnetic Material for High Saturation and Low Coercivity
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Solution Overview
Problem
Current magnetic materials lack a balance between high magnetic saturation and low coercivity, making them unsuitable for applications requiring both high permeability and low magnetocrystalline anisotropy.
Innovation Solution
The development of magnetic materials comprising α″-Fe16(NxZ1-x)2 or α′-Fe8(NxZ1-x) phases, where Z includes C, B, or O, with controlled ratios of N and Z atoms, which are formed using techniques such as chemical vapor deposition, liquid phase epitaxy, and ion implantation to achieve a balance between magnetic saturation and coercivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional magnetic materials are used to achieve high magnetic saturation, then magnetic saturation is improved, but coercivity becomes too high
Solution Approach 1:
The patent creates a composite magnetic material system comprising multiple phases (α-Fe, α''-Fe16N2, and Fe16(NxZ1-x)2 where Z=C, B, or O) with controlled volume ratios. The soft magnetic α-Fe phase provides high magnetic saturation while the interstitial compound phases provide magnetic anisotropy control, achieving low coercivity through the composite structure rather than a single material phase.
Solution Approach 2:
The patent systematically varies compositional parameters (nitrogen content x, substituent element content 1-x, and phase volume ratios) to optimize magnetic properties. By controlling the ratio of α''-Fe16N2 to Fe16(NxZ1-x)2 phases and adjusting the interstitial atom composition, the material achieves simultaneous high saturation and low coercivity through parameter optimization.
2Adaptability or versatility
If magnetic materials are designed for high permeability, then permeability is improved, but magnetocrystalline anisotropy becomes too high
Solution Approach 1:
The composite structure combines soft magnetic α-Fe phase (high permeability) with interstitial compound phases (magnetic anisotropy control). The α-Fe phase dominates the permeability response while the interstitial compounds reduce magnetocrystalline anisotropy through their crystal structure and magnetic moment orientation, enabling simultaneous high permeability and low anisotropy.
Solution Approach 2:
The patent creates local regions with different magnetic characteristics: the α-Fe domains provide high permeability and soft magnetic response, while the Fe16(NxZ1-x)2 interstitial compound domains provide magnetic anisotropy control. This spatial differentiation of magnetic properties within the composite enables simultaneous optimization of permeability and anisotropy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
These materials exhibit high magnetic saturation and low coercivity, making them suitable for applications in transformer cores, magnetic recording media, and microwave devices, while also possessing high permeability and frequency response.
Implementation Method 1
the magnetic material including α″-Fe16(NxZ1-x)2 or α′-Fe8(NxZ1-x), or a mixture of at least one of α″-Fe16N2 or α′-Fe8N and at least one of α″-Fe16Z2 or α′-Fe8Z may include a relatively high magnetic saturation
Implementation Method 2
the magnetic material including α″-Fe16(NxZ1-x)2 or α′-Fe8(NxZ1-x), or a mixture of at least one of α″-Fe16N2 or α′-Fe8N and at least one of α″-Fe16Z2 or α′-Fe8Z may include a relatively low coercivity
Implementation Method 3
Magnetic material including α″-Fe16(NxZ1-x)2 or a mixture of α″-Fe16N2 and α″-Fe16Z2 may be formed by any of a variety of techniques. Example techniques described herein include chemical vapor deposition (CVD)
Implementation Method 4
Magnetic material including α″-Fe16(NxZ1-x)2 or a mixture of α″-Fe16N2 and α″-Fe16Z2 may be formed by any of a variety of techniques. Example techniques described herein include chemical vapor deposition (CVD), liquid phase epitaxy (LPE), sputtering, ion implantation
Implementation Method 5
Magnetic material including α″-Fe16(NxZ1-x)2 or a mixture of α″-Fe16N2 and α″-Fe16Z2 may be formed by any of a variety of techniques. Example techniques described herein include chemical vapor deposition (CVD), liquid phase epitaxy (LPE), sputtering, ion implantation, nitridizing and carbonizing a workpiece under an applied strain
Data Source
AI summary
A magnetic material may include α″-Fe16(NxZ1-x)2 or a mixture of α″-Fe16N2 and α″-Fe16Z2, where Z includes at least one of C, B, or O, and x is a number greater than zero and less than one. In some examples, the magnetic material including α″-Fe16(NxZ1-x)2 or a mixture of α″-Fe16N2 and α″-Fe16Z2 may include a relatively high magnetic saturation, such as greater than about 219 emu/gram, greater than about 242 emu/gram, or greater than about 250 emu/gram. In addition, in some examples, the magnetic material including α″-Fe16(NxZ1-x)2 or a mixture of α″-Fe16N2 and α″-Fe16Z2 may include a relatively low coercivity. Techniques for forming the magnetic material are also described.