Soft Magnetic Nanocomposite Alloy for High-Temperature Transformers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing soft magnetic materials, such as crystalline alloys, fail to meet the requirements for high-frequency and high-temperature applications due to their crystalline structure, leading to limitations in saturation magnetic flux density, Curie temperature, and core loss, making them unsuitable for advanced transformer technologies.
Innovation Solution
A soft magnetic nanocomposite alloy comprising an amorphous phase and a crystalline phase, with a composition of (Fe1-x-yCoxMy)100-a-b-cTaBbNc, where M is Ni or Mn, T is Nb, W, Ta, Zr, Hf, Ti, Cr, Cu, Mo, and N is Si, Ge, C, P, or Al, is developed, allowing for fine grain nanocrystalline particles embedded in an amorphous matrix, enhancing magnetic properties like saturation flux density and Curie temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crystalline soft magnetic alloys are used, then the material structure is stable and easy to manufacture, but the saturation magnetic flux density, Curie temperature, and core loss performance are insufficient for high-frequency applications
Solution Approach 1:
The patent employs a nanocomposite structure consisting of nanocrystalline particles (1-20 nm) embedded in an amorphous matrix. This composite structure combines the advantages of both crystalline and amorphous phases: the nanocrystalline regions provide high saturation magnetic flux density and stable magnetic properties, while the amorphous matrix contributes to high Curie temperature and low core loss. The specific composition (Fe1-x-yCoxMy)100-a-b-cTaBbNc with controlled phases achieves superior magnetic performance for high-frequency applications.
Solution Approach 2:
The patent utilizes field heat treatment to transform the material structure from fully amorphous to a nanocomposite state with specific crystalline phase distribution. By controlling heat treatment parameters (temperature, time, and applied magnetic field strength of 0.5-2.0 Tesla), the material develops nanocrystalline particles with controlled size and distribution, optimizing the balance between saturation flux density and Curie temperature.
2Loss of energy
If amorphous alloys are used to achieve low core loss and high permeability, then magnetic properties are improved, but the saturation magnetic flux density and Curie temperature remain limited
Solution Approach 1:
The nanocomposite structure with nanocrystalline particles (1-20 nm) dispersed in an amorphous matrix resolves this contradiction by combining the low core loss characteristics of the amorphous phase with the high saturation magnetic flux density of the nanocrystalline phase. The interfacial effects between the two phases further enhance magnetic properties while maintaining low energy loss.
3Loss of energy
If amorphous alloys are used, then low core loss and high permeability are achieved, but the material cannot maintain these properties at high temperatures and high frequencies
Solution Approach 1:
Field heat treatment transforms the material from a fully amorphous structure to a nanocomposite structure with nanocrystalline particles embedded in the amorphous matrix. This structural transformation significantly improves thermal stability and maintains low core loss at high temperatures and frequencies by creating a more stable magnetic phase distribution that resists thermal degradation.
Solution Approach 2:
The nanocomposite structure provides superior thermal stability compared to fully amorphous or fully crystalline materials. The nanocrystalline particles act as stable magnetic centers that maintain magnetic properties at elevated temperatures, while the amorphous matrix continues to provide low core loss characteristics, achieving both low energy loss and high temperature stability simultaneously.
4Reliability
If fine crystalline particles are added to amorphous alloys to improve saturation flux density, then magnetic strength increases, but the amorphous structure stability and manufacturing complexity are affected
Solution Approach 1:
Field heat treatment provides a controlled method to generate nanocrystalline particles within the amorphous matrix by applying magnetic fields during heat treatment. This process precisely controls particle size (1-20 nm) and distribution, achieving high saturation magnetic flux density while maintaining manufacturing feasibility through a single-step heat treatment process.
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 nanocomposite alloy achieves a saturation flux density greater than 1 Tesla, a linear magnetization curve up to 700 A/m, and a Curie temperature above 450°C, making it suitable for high-temperature and wide-frequency-range applications, including transformers and wire coils.
Implementation Method 1
A soft magnetic nanocomposite alloy comprising an amorphous phase and a crystalline phase... (Fe1-x-yCoxMy)100-a-b-cTaBbNc... saturation flux density greater than 1 Tesla... Curie temperature above 450°C
Implementation Method 2
A soft magnetic nanocomposite alloy comprising an amorphous phase and a crystalline phase... fine grain nanocrystalline particles embedded in an amorphous matrix
Data Source
AI summary
The invention discloses a soft magnetic amorphous alloy and a soft magnetic nanocomposite alloy formed from the amorphous alloy. Both alloys comprise a composition expressed by the following formula:(Fe1-x-yCoxMy)100-a-b-cTaBbNc where, M is at least one element selected from the group consisting of Ni and Mn; T is at least one element selected from the group consisting of Nb, W, Ta, Zr, Hf, Ti, Cr, Cu, Mo, V and combinations thereof, and the content of Cu when present is less than or equal to 2 atomic %; N is at least one element selected from the group consisting of Si, Ge, C, P and Al; and 0.01≦x+y≦0.5; 0≦y≦0.4; 1≦a≦5 atomic %; 10≦b≦30 atomic %; and 0≦c≦10 atomic %. A core, which may be used in transformers and wire coils, is made by charging a furnace with elements necessary to form the amorphous alloy, rapidly quenching the alloy, forming a core from the alloy; and heating the core in the presence of a magnetic field to form the nanocomposite alloy. The resulting nanocomposite alloy of the core comprises the amorphous alloy having embedded therein, fine grain nanocrystalline particles, about 90% of which are 20 nm in any dimension.