Fe-Based Amorphous Alloy Powder for Dust Cores
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Solution Overview
Problem
Fe-based amorphous alloy powders for dust cores and coil-embedded dust cores face challenges in achieving low glass transition temperatures and high corrosion resistance while maintaining high magnetic permeability and low core loss, especially when used in high-frequency applications.
Innovation Solution
The Fe-based amorphous alloy powder composition of (Fe 100-a-b-c-x-y-z-t Ni a Sn b Cr c P x C y B z Si t ) 100-α M α, where 0 at%≤a≤10, 0 at%≤b≤3, 0 at%≤c≤6, 6.8 at%≤x≤10.8, 2.2 at%≤y≤9.8, 0 at%≤z≤4.2, and 0 at%≤t≤3.9, with M being Ti, Al, Mn, Zr, Hf, V, Nb, Ta, Mo, and W, and α between 0.04 wt% and 0.6 wt%, is used to reduce glass transition temperatures and enhance corrosion resistance through a thin passivation layer, thereby improving magnetic permeability and reducing core loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the glass transition temperature (Tg) of the Fe-based amorphous alloy powder is set low to enable heat treatment at practical temperatures, then the heat treatment can be performed without damaging coated wire and binding material, but the corrosion resistance deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition ratios of multiple alloying elements (Ni: 3-10 at%, Sn: 1-3 at%, Cr: 2-6 at%, P: 7-11 at%, C: 2-10 at%, B: 0.5-4 at%, Si: 0.5-4 at%) to simultaneously achieve low glass transition temperature (673-723 K) and high corrosion resistance. This compositional parameter optimization allows the material to exhibit both low Tg for practical heat treatment and high corrosion resistance for reliable operation.
Solution Approach 2:
The patent employs composite material principles by creating a multi-element amorphous alloy system that combines Fe with Ni, Sn, Cr, P, C, B, and Si. This composite alloy structure enables the material to possess multiple desirable properties simultaneously: low glass transition temperature for heat treatability, high corrosion resistance through protective oxide layer formation, and excellent magnetic characteristics for transformer applications.
2Temperature
If the glass transition temperature (Tg) is set low to allow practical heat treatment, then heat treatment can be performed below heat resistance temperature of coated wire and binding material, but magnetic characteristics deteriorate due to poor corrosion resistance
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition ratios of multiple alloying elements (Ni: 3-10 at%, Sn: 1-3 at%, Cr: 2-6 at%, P: 7-11 at%, C: 2-10 at%, B: 0.5-4 at%, Si: 0.5-4 at%) to simultaneously achieve low glass transition temperature (673-723 K) and high corrosion resistance. This compositional parameter optimization allows the material to exhibit both low Tg for practical heat treatment and high corrosion resistance for reliable operation.
Solution Approach 2:
The patent employs composite material principles by creating a multi-element amorphous alloy system that combines Fe with Ni, Sn, Cr, P, C, B, and Si. This composite alloy structure enables the material to possess multiple desirable properties simultaneously: low glass transition temperature for heat treatability, high corrosion resistance through protective oxide layer formation, and excellent magnetic characteristics for transformer applications.
3Reliability
If heat treatment is performed to reduce stress strain in powder formation and molding, then the core performance improves, but the glass transition temperature must be low enough to avoid damaging coated wire and binding material
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition ratios of multiple alloying elements (Ni: 3-10 at%, Sn: 1-3 at%, Cr: 2-6 at%, P: 7-11 at%, C: 2-10 at%, B: 0.5-4 at%, Si: 0.5-4 at%) to simultaneously achieve low glass transition temperature (673-723 K) and high corrosion resistance. This compositional parameter optimization allows the material to exhibit both low Tg for practical heat treatment and high corrosion resistance for reliable operation.
Solution Approach 2:
The patent employs composite material principles by creating a multi-element amorphous alloy system that combines Fe with Ni, Sn, Cr, P, C, B, and Si. This composite alloy structure enables the material to possess multiple desirable properties simultaneously: low glass transition temperature for heat treatability, high corrosion resistance through protective oxide layer formation, and excellent magnetic characteristics for transformer applications.
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
This composition effectively decreases glass transition temperatures, enhances corrosion resistance, and increases magnetic permeability, resulting in reduced core loss and improved high-frequency performance for dust cores and coil-embedded dust cores.
Implementation Method 1
enhance corrosion resistance through a thin passivation layer
Implementation Method 2
increases magnetic permeability, resulting in reduced core loss
Data Source
Figure 1~2(a)
Figure 2(b)~3
Figure 4(a)~4(c)
AI summary
[Object] To provide in particular an Fe-based amorphous alloy powder which has a low glass transition temperature (Tg) and an excellent corrosion resistance and which is used for a dust core or a coil-embedded dust core, each having high magnetic characteristics. [Solution] An Fe-based amorphous alloy powder of the present invention has a composition represented by (Fe100-a-bc-x-y-z-tNiaSnbCrcPxCyBzSit)100-αMα. In this composition, 0 at%≤a≤10 at%, 0 at%≤b≤3 at%, 0 at%≤c≤6 at%, 6.8 at%≤x≤10.8 at%, 2.2 at%≤y≤9.8 at%, 0 at%≤z≤4.2 at%, and 0 at%≤t≤3.9 at% hold, a metal element M is at least one selected from the group consisting of Ti, Al, Mn, Zr, Hf, V, Nb, Ta, Mo, and W, and the addition amount α of the metal element M satisfies 0.04 wt%≤α≤0.6 wt%. Accordingly, besides a decrease of Tg, an excellent corrosion resistance and high magnetic characteristics can be obtained.