Fe-Based Amorphous Alloy Clusters for High-Frequency Soft Magnetics
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Solution Overview
Problem
Current soft magnetic materials, such as commercial FINEMET nanocrystalline alloy ribbons, face limitations in high-frequency permeability and saturation flux density, hindering the development of power electronic components towards miniaturization, high power, and high frequency applications.
Innovation Solution
A Fe-based amorphous alloy containing subnanometer-scale ordered clusters is designed and prepared, featuring a composition of Fe a Si b B c (Cu d X e )M f M' g, where X is Ti, Zr, or Hf, and M and M' are various elements. This alloy is heat-treated to form a nanocrystalline alloy with improved grain size distribution and soft magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If commercial FINEMET nanocrystalline alloy ribbons are used, then high-frequency permeability is improved, but saturation flux density is reduced
Solution Approach 1:
The invention changes the microstructural parameters by introducing subnanometer-scale ordered clusters (0.5-2 nm) into the amorphous matrix, which serve as nucleation sites for nanocrystalline grain formation. This controlled nucleation achieves finer grain size distribution (5-20 nm) that simultaneously improves high-frequency permeability and maintains high saturation flux density, resolving the trade-off between these two parameters.
Solution Approach 2:
The invention creates a composite microstructure consisting of an amorphous alloy matrix containing dispersed subnanometer-scale ordered clusters of Cu-X elements (where X is Ti, Zr, or Hf). This composite structure at the nanoscale enables both high permeability through the amorphous phase and high saturation flux density through the Fe-rich nanocrystalline regions, overcoming the limitations of conventional single-phase materials.
2Volume of moving object
If ribbon thickness is reduced for miniaturization, then device size is reduced, but manufacturing yield decreases
Solution Approach 1:
The invention performs preliminary action by forming subnanometer-scale ordered clusters during the amorphous alloy solidification process. These pre-formed clusters act as uniform nucleation sites that control subsequent nanocrystalline grain growth, enabling production of ribbons with thickness of 16 μm or above while maintaining consistent fine grain size distribution and high manufacturing yield, thus avoiding the yield problems associated with ultra-thin ribbons.
3Force
If vacuum transverse magnetic field heat treatment is applied, then high-frequency permeability is increased, but process complexity increases
Solution Approach 1:
The invention performs preliminary action by pre-forming subnanometer-scale ordered clusters during solidification that serve as controlled nucleation sites. This preliminary structuring enables subsequent heat treatment to proceed under simpler conditions while achieving superior and more uniform nanocrystalline grain refinement, reducing the need for complex multi-stage magnetic field heat treatment processes.
Solution Approach 2:
The invention changes the microstructural parameters by introducing ordered clusters with specific size (0.5-2 nm) and composition (Cu-X where X is Ti, Zr, or Hf). These parameter changes create a more favorable nucleation structure that responds better to simpler heat treatment conditions, achieving high-frequency permeability improvement without requiring excessively complex processing parameters or equipment.
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
The resulting nanocrystalline alloy achieves an effective permeability of 35000 or above and a saturation flux density of 1.3 T or above at 100 kHz, addressing the limitations of existing materials and supporting the development of high-frequency and miniaturized power electronic components.
Implementation Method 1
The Fe-based amorphous alloy is a composite composed of an amorphous alloy matrix with atoms arranged completely disorderedly and ordered atom clusters with a size of 0.5-2 nm homogeneously dispersed in the matrix
Data Source
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AI summary
A Fe-based amorphous alloy containing subnanometer-scale ordered clusters, and a preparation method and a nanocrystalline alloy derivative thereof. The composition expression of the Fe-based amorphous alloy is FeaSibBc(CudXe)MfM'g, and X is at least one of Ti, Zr and Hf, M is at least one of V, Ta and Nb, and M' at least one of Co, Ni, C, P, Ge, Cr, Mn, W, Zn, Sn, Sb and Mo; a, b, c, d, e, f and g respectively represent the atomic percent (percentage of the number of atoms) of the corresponding element, and satisfy: 74≤a≤82, 8≤b≤15, 4≤c≤10, 0.5≤d≤1.2, 0.4≤e≤1.8,1≤f≤3.5, 0≤g≤1, 0.8≤e/d≤1.5 and a+b+c+d+e+f+g=100; the Fe-based amorphous alloy is a composite material composed of an amorphous alloy matrix with atoms arranged in complete disorder and ordered atomic clusters having the size ranging from 0.5 nm to 2 nm uniformly dispersed and distributed in the matrix. The Fe-based amorphous alloy has ultrahigh permeability: the permeability at the frequency of 100 kHz is more than 35000, and the saturation flux density more than 1.3 T.