Fe-Co Soft Magnetic Alloy Composition for Lower Cost and Cold Workability
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Solution Overview
Problem
The high cost and brittleness associated with high Co content in Fe—Co alloys for soft magnetic members, which affect producibility and cold workability, necessitate a composition that balances magnetic properties and cost while ensuring excellent producibility and cold workability.
Innovation Solution
A Fe—Co alloy composition with 10.00%≤Co≤20.00%, 0.10%≤Si<2.0%, 0.10%≤Al<2.0%, and 0.01%<M<0.10% (where M is Ta or Y), along with optional V and Cr, and controlled impurities, to achieve high producibility and magnetic properties, including a core loss of 200 W/kg or less at 1.5 T and 1 kHz.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of Co is added to Fe to increase saturation magnetic flux density, then magnetic properties are improved, but cost increases and brittleness occurs
Solution Approach 1:
The patent optimizes the Co content parameter to a specific range (10-20 mass%) rather than using high amounts, and introduces additional alloying elements (Si: 0.1-2.0%, Al: 0.1-2.0%, M: 0.01-0.10%) to achieve the desired magnetic properties with reduced Co, thereby resolving the contradiction between magnetic performance and manufacturability
Solution Approach 2:
The patent creates a composite alloy system combining Fe with multiple elements (Co, Si, Al, and optional V, Cr, Ta, Y) where each element contributes specific properties. This composite approach allows achieving high saturation magnetic flux density and low core loss without relying solely on high Co content, thus improving producibility while maintaining magnetic properties
2Reliability
If a large amount of Co is added to Fe to increase saturation magnetic flux density, then magnetic properties are improved, but cold workability deteriorates
Solution Approach 1:
The patent changes the compositional parameters by limiting Co to 10-20 mass% (avoiding excessive Co that causes brittleness) and adding specific amounts of Si, Al, and M elements. This parameter optimization ensures the alloy maintains ductility and cold workability while achieving the required magnetic properties
Solution Approach 2:
The patent introduces intermediary elements (Si, Al, V, Cr, Ta, Y) that act as mediators to enhance the alloy's cold workability. These elements improve the material's formability and reduce brittleness, allowing the alloy to be cold-formed into complex shapes while maintaining magnetic properties
3Quantity of substance
If Co content is reduced to lower cost, then cost decreases, but magnetic properties deteriorate
Solution Approach 1:
The patent develops a composite alloy formulation where Fe serves as the base and is combined with optimized amounts of Co (10-20%), Si (0.1-2.0%), Al (0.1-2.0%), and optional elements (V, Cr, Ta, Y). This composite structure compensates for reduced Co content by leveraging the synergistic effects of multiple elements to maintain high saturation magnetic flux density and low core loss while reducing cost
Solution Approach 2:
The patent changes the alloy composition parameters to achieve a cost-effective formulation. By optimizing the Co content to 10-20 mass% (lower than conventional high-Co alloys) and introducing Si, Al, and trace elements, the patent achieves a balance between cost reduction and maintaining required magnetic properties
4Ease of operation
If Co content is controlled to improve cold workability, then cold workability is improved, but magnetic properties may deteriorate
Solution Approach 1:
The patent creates a multi-element composite alloy where Fe, Co, Si, Al, and optional elements (V, Cr, Ta, Y) work synergistically. The Co content is controlled to 10-20% for good cold workability, while Si and Al contribute to magnetic properties, and trace elements provide additional benefits. This composite approach ensures both cold workability and magnetic properties are satisfied simultaneously
Solution Approach 2:
The patent optimizes multiple compositional parameters together: Co (10-20%) for cold workability, Si (0.1-2.0%) and Al (0.1-2.0%) for magnetic properties, and trace elements (M: 0.01-0.10%, V/Cr: ≤2.0%) for fine-tuning properties. This multi-parameter optimization ensures the alloy achieves both excellent cold workability and satisfactory magnetic properties
Data Source
AI summary
The present invention relates to a Fe—Co alloy for a soft magnetic member, including an alloy composition that includes, in terms of mass %, 10.00%<Co≤20.00%, 0.10%≤Si<2.0%, 0.10%≤Al<2.0%, and 0.01%<M<0.10%, provided that M is Ta or Y; with the balance being Fe and unavoidable impurities, and relates to a soft magnetic member.