Fe-Ga-Al Magnetostrictive Thin-Sheet Material for High-Frequency Transducers
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Solution Overview
Problem
Fe—Ga-based magnetostrictive thin-sheet materials face challenges with low ductility, anti-oxidization issues, and complex manufacturing processes, including excessive rolling passes and repeated annealing steps, which lead to eddy current losses and limited applicability at higher frequencies.
Innovation Solution
A Fe—Ga—Al-based magnetostrictive thin-sheet material with specific atomic ratios and a processing method involving smelting, forging, hot rolling, cold rolling, and heat preservation to achieve improved ductility and anti-oxidization, reducing rolling passes and eliminating the need for sheathing, resulting in a material with enhanced mechanical properties and reduced eddy current loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Fe-Ga-based magnetostrictive thin-sheet materials are used, then high magnetostriction coefficients are achieved, but low ductility and anti-oxidation issues occur
Solution Approach 1:
The patent develops a Fe-Ga-Al-based alloy with specific composition ranges (Fe: 70-85 wt%, Ga: 10-25 wt%, Al: 1-10 wt%) that combines the high magnetostriction properties of Fe-Ga alloys with the improved ductility and anti-oxidation characteristics provided by aluminum addition, creating a composite material system that resolves the contradiction between magnetostriction performance and mechanical properties
Solution Approach 2:
The patent optimizes the chemical composition parameters within specific ranges to achieve the desired balance between magnetostriction coefficient and ductility. By controlling the aluminum content at 1-10 wt% and adjusting Fe-Ga ratios, the material exhibits both high magnetostriction (>100 ppm) and improved formability without severe embrittlement
2Reliability
If complex manufacturing processes with excessive rolling passes and repeated annealing are used, then material properties are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent incorporates alloying elements (particularly Al, and optionally V, Cr, Ti, B) during the initial smelting stage to pre-establish the desired microstructure and properties. This preliminary compositional design enables the material to achieve target properties with fewer subsequent processing steps, reducing manufacturing complexity
Solution Approach 2:
The patent reduces the number of rolling passes from traditional excessive amounts to a optimized range of 5-20 passes, and limits annealing to 1-3 stages with specific temperature ranges (400-700°C), thereby simplifying the manufacturing process while maintaining material quality through compositional optimization
3Ease of manufacture
If traditional rolling processes are used, then material is formed, but eddy current losses occur at higher frequencies
Solution Approach 1:
The patent produces thin-sheet materials with controlled thickness and refined grain structure through optimized rolling and heat treatment processes. The thin-sheet geometry inherently reduces eddy current paths, while the aluminum-containing alloy composition provides improved electrical resistivity, collectively reducing eddy current losses at higher frequencies
Solution Approach 2:
The patent controls the thickness and microstructure parameters of the final product to optimize the balance between formability and electrical properties. The specific composition ranges and processing parameters produce a fine-grained structure that reduces eddy current losses while maintaining adequate ductility for manufacturing
4Reliability
If rare earth giant magnetostrictive materials are used, then very high magnetostriction coefficients are achieved, but intrinsic embrittlement and poor environmental tolerance occur
Solution Approach 1:
The patent replaces rare earth elements with an Fe-Ga-Al composite system that achieves comparable or superior magnetostriction properties (>100 ppm, potentially up to 200-300 ppm) without the intrinsic embrittlement associated with Laves phase intermetallic compounds. The aluminum addition specifically addresses the embrittlement issue while maintaining high magnetostriction
Solution Approach 2:
The patent substitutes expensive rare earth elements with abundant and cost-effective Fe-Ga-Al alloy system, achieving similar functional performance at lower material cost and without the environmental tolerance issues of rare earth-based materials
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 Fe—Ga—Al-based material exhibits high magnetostriction coefficients, excellent plasticity, and improved anti-oxidization, enabling efficient production with reduced complexity and cost, suitable for high-frequency applications in transducers and sensors.
Implementation Method 1
The phenomenon that ferromagnetic and ferrimagnetic materials undergo a small change in length and volume due to change in the magnetization state is referred to as magnetostriction
Implementation Method 2
A Fe—Ga—Al-based magnetostrictive thin-sheet material... with excellent plasticity and improved anti-oxidization
Data Source
AI summary
The present invention relates to a Fe—Ga—Al-based magnetostrictive thin-sheet material and a process for preparation thereof. The raw materials used for production of the thin-sheet material is composed of the components according to the general Formula, Fe100-x-y-zGaxAlyMz, wherein x=10-30, y=1-10, and z=0.1-5, and M is any one, or more elements selected from V, Cr, Zr, Sb, Sn, Ti, SiC.