FeCoBSiPCu Alloy Powder for High Yield Magnetic Components
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Solution Overview
Problem
Existing Fe-based amorphous alloy powders for electronic components like noise filters and choke coils face challenges in achieving high saturation magnetic flux density and low coercive force, while maintaining a large particle diameter, which is essential for improving yield and magnetic characteristics.
Innovation Solution
The development of FeCoBSiPCu alloy powder with a composition formula of Fe100-a-b-c-d-e-f Coa Bb Si c P d Cu e C f, where 3.5 ≤ a ≤ 4.5 at%, 6 ≤ b ≤ 15 at%, 2 ≤ c ≤ 11 at%, 3 ≤ d ≤ 5 at%, 0.5 ≤ e ≤ 1.1 at%, and 0 ≤ f ≤ 2 at%, primarily featuring an amorphous phase or a mixed amorphous and crystal phase structure, to enhance amorphous forming ability and magnetic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the particle diameter of alloy powder is increased to improve yield, then productivity is improved, but saturation magnetic flux density decreases and coercive force increases
Solution Approach 1:
The invention changes the chemical composition parameters of the alloy by precisely controlling the content of Co (3.5-4.5 at%), B (6-15 at%), Si (2-11 at%), P (3-5 at%), Cu (0.5-1.1 at%), and C (0-2 at%). This parameter optimization enables the alloy to form an amorphous phase structure that maintains excellent magnetic characteristics (saturation magnetic flux density ≥1.6 T and coercive force ≤100 A/m) even when the particle diameter is large (90 μm or less), thus resolving the contradiction between yield improvement and magnetic property maintenance.
2Ease of manufacture
If Fe content is reduced to improve amorphous forming ability, then ease of manufacture is improved, but saturation magnetic flux density decreases
Solution Approach 1:
The invention creates a composite alloy system FeCoBSiPCuC that combines multiple elements with complementary functions. Co and B serve as primary amorphous-forming elements, while Fe provides magnetic properties. The synergistic combination of these elements enables the alloy to achieve both high amorphous forming ability and high saturation magnetic flux density, resolving the contradiction between ease of manufacture and magnetic performance.
3Ease of manufacture
If Co content is increased to improve amorphous forming ability, then ease of manufacture is improved, but device complexity increases due to composition control
Solution Approach 1:
The invention optimizes the Co content to a specific range (3.5-4.5 at%) that provides sufficient amorphous forming ability without excessive complexity. This precise parameter control, combined with coordinated adjustment of other elements (B: 6-15 at%, Si: 2-11 at%, P: 3-5 at%, Cu: 0.5-1.1 at%, C: 0-2 at%), achieves the desired balance between manufacturability and composition control complexity.
Data Source
AI summary
Alloy powder of a composition formula Fe100-a-b-c-d-e-fCoaBbSicPdCueCf having an amorphous phase as a main phase is provided. Parameters satisfy the following conditions: 3.5 ≤ a ≤4.5 at%, 6 ≤ b ≤ 15 at%, 2 ≤ c ≤ 11 at%, 3 ≤ d ≤ 5 at%, 0.5 ≤ e ≤ 1.1 at%, and 0 ≤ f ≤ 2 at%. With this composition, the alloy powder has good magnetic characteristics even when it has a large particle diameter such as 90 µm. Therefore, yield thereof is improved.