Fe-B-P-Cu Soft Magnetic Alloy Amorphous Phase Formation
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Solution Overview
Problem
Conventional magnetic core materials struggle to balance high saturation magnetic flux density with excellent soft magnetic properties, capability of forming an amorphous phase, and efficient powder production, leading to limitations in applications such as miniaturized electronic devices.
Innovation Solution
A soft magnetic alloy with a composition of Fe 70 atomic % or more, B 5-25 atomic %, Cu 1.5 atomic % or less, and P 10 atomic % or less, formed by rapidly cooling and solidifying an Fe-based alloy, which allows for the deposition of α-Fe crystal phase within an amorphous phase, enabling the production of ribbons and powders with excellent magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If Fe-based amorphous material is used, then core loss is reduced due to no magnetic crystalline anisotropy, but capability of forming amorphous phase is low limiting ribbon thickness to 20-30 μm
Solution Approach 1:
The patent modifies the chemical composition parameters of the Fe-based alloy by adding specific amounts of B (5-25 atomic %), P (10 atomic % or less), and Cu (1.5 atomic % or less). These compositional changes enhance the alloy's capability to form an amorphous phase, enabling production of ribbons thicker than 20-30 μm while maintaining low core loss properties.
2Reliability
If Co-based amorphous material is used, then soft magnetic property is excellent with zero-magnetostriction, but saturation magnetic flux density is as low as ferrite and Co is expensive
Solution Approach 1:
The patent changes the compositional parameters by using Fe as the principal component (70 atomic % or more) instead of Co, while adding B, P, and Cu to achieve amorphous phase formation. This Fe-based composition attains saturation magnetic flux density of 1.5 T or more, exceeding both ferrite and Co-based amorphous materials, while maintaining excellent soft magnetic properties.
3Reliability
If conventional nanocrystalline materials are used, then magnetic coercive force is low and magnetic permeability is high, but capability of forming amorphous phase is low
Solution Approach 1:
The patent modifies the compositional parameters by incorporating B (5-25 atomic %) and P (10 atomic % or less) along with Fe (70 atomic % or more), which significantly enhances the capability to form an amorphous phase. This enables direct production of amorphous powder by water atomization while achieving low magnetic coercive force and high magnetic permeability.
4Quantity of substance
If Fe, Fe-Si, Fe-Si-Cr are used, then saturation magnetic flux density is high, but soft magnetic property is inferior
Solution Approach 1:
The patent creates a composite alloy system combining Fe with B, P, and Cu elements. The Fe provides high saturation magnetic flux density, while B, P, and Cu work synergistically to form an amorphous phase structure that delivers excellent soft magnetic properties, achieving both high saturation magnetic flux density (1.5 T or more) and superior soft magnetic characteristics.
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 alloy achieves a high saturation magnetic flux density and excellent soft magnetic properties, enabling the production of wound, multilayer, and dust cores with improved magnetic performance and manufacturing efficiency.
Implementation Method 1
formed by rapidly cooling and solidifying an Fe-based alloy
Implementation Method 2
allows for the deposition of α-Fe crystal phase within an amorphous phase
Data Source
AI summary
A soft magnetic alloy contains P, B, and Cu as essential components. As a preferred example, an Fe-based alloy contains Fe of 70 atomic % or more, B of 5 atomic % to 25 atomic %, Cu of 1.5 atomic % or less (excluding zero), and P of 10 atomic or less (excluding zero).