Fe-Based Amorphous Alloy Composition for Low-Loss Transformer Ribbons
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Solution Overview
Problem
Fe-based amorphous alloys used in iron cores for power and high-frequency transformers face challenges in achieving low iron loss and high magnetic flux density, as existing compositions do not adequately optimize the balance of elements for improved soft magnetic properties.
Innovation Solution
The development of an Fe-based amorphous alloy with specific compositions, including varying ranges of B, Si, C, Al, P, and Fe, along with optional inclusion of Ni, Cr, and Co, to optimize the amorphous structure and magnetic properties, allowing for low iron loss and high saturation magnetic flux density without the need for additional elements like Mo.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional Fe-based amorphous alloy compositions are used, then basic magnetic properties are achieved, but iron loss is high and saturation magnetic flux density is insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition ratios of alloying elements (B: 8-18 atom%, Si: 2-9 atom%, C: 0.1-5 atom%, Al: 0.005-1.5 atom%, P: 0-1 atom%, Mn: 0-0.3 atom%, Fe: 78-86 atom%) to optimize the amorphous structure. This compositional parameter optimization reduces iron loss while maintaining high saturation magnetic flux density of 1.60 T or more, resolving the contradiction between energy loss and magnetic performance reliability.
2Reliability
If additional elements like Mo are added to improve magnetic properties, then soft magnetic properties are enhanced, but alloy complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the need for additional elements like Mo by optimizing the Fe-B-Si-C-Al-P-Mn system. The invention achieves excellent soft magnetic properties (iron loss ≤0.095 W/kg, saturation magnetic flux density ≥1.60 T) using only these seven elements, thereby reducing alloy composition complexity while maintaining or improving magnetic performance.
Solution Approach 2:
The patent applies multi-functionality by having the Fe-B-Si-C-Al-P-Mn system perform multiple functions simultaneously: Fe provides the base magnetic properties, B and Si form the amorphous structure, C and Al optimize magnetic performance, P and Mn further enhance soft magnetic properties. This universal element combination replaces the need for specialized elements like Mo, reducing complexity while achieving superior magnetic properties.
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 optimized alloy achieves a saturation magnetic flux density of 1.60 T or more and an iron loss of 0.095 W/kg or less at 1.3 T and 50 Hz, enhancing soft magnetic properties and workability, particularly in the form of an Fe-based amorphous alloy ribbon suitable for transformer applications.
Implementation Method 1
The melt was ejected through a slot nozzle onto a water-cooled copper wheel rotating at a linear speed of 20 m/s to thereby quench and solidify the melt
Implementation Method 2
Fe: 78.00% or more and 86.00% or less, and balance: impurities and having an amorphous structure
Data Source
AI summary
The present invention has as its object the provision of an Fe-based amorphous alloy and Fe-based amorphous alloy ribbon excellent in soft magnetic properties having a low iron loss and a high saturation magnetic flux density. The Fe-based amorphous alloy excellent in soft magnetic properties of the present invention comprises, by atom %, B: 8.0% or more and 18.0% or less, Si: 2.0% or more and 9.0% or less, C: 0.10% or more and 5.00% or less, Al: 0.005% or more and 1.50% or less, P: 0% or more and less than 1.00%, Mn: 0% or more and 0.30% or less, Fe: 78.00% or more and 86.00% or less, and balance: impurities and has an amorphous structure.