Soft Magnetic Alloy Composition for High Flux Density
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Solution Overview
Problem
Current soft magnetic alloys face challenges in achieving high saturated magnetic flux density while maintaining low coercive force and affordability, with existing materials like permendur being expensive and electromagnetic steel sheets having limited magnetic flux density.
Innovation Solution
A soft magnetic alloy composition containing Ni, at least one element selected from Al, Si, and V, with specific content ratios plotted within defined regions, optionally including Cr and Mo for enhanced electric resistance and corrosion resistance, and additional elements like Pb, Bi, Ca, Te, and Se for improved machinability, to achieve high saturated magnetic flux density and low coercive force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a Fe-Co alloy (permendur) is used to achieve high magnetic flux density, then the magnetic flux density increases, but the cost increases significantly due to large Co content
Solution Approach 1:
The patent changes the compositional parameters by replacing Co with Ni and optimizing the content ratios of Ni (0.1-11.0 mass%), Al+Si+V (0.01-10.00 mass%), and other elements to achieve high magnetic flux density (1.7 T or more) while reducing cost. This parameter optimization resolves the contradiction between performance and manufacturing cost.
Solution Approach 2:
The patent substitutes expensive Co with cheaper Ni and common elements (Al, Si, V, Cr, Mo) to create a cost-effective alloy composition that maintains high magnetic flux density, effectively replacing expensive materials with more economical alternatives.
2Ease of manufacture
If electromagnetic steel sheet is used to reduce cost, then the cost decreases, but the magnetic flux density remains limited and cannot achieve 1.7 T or larger
Solution Approach 1:
The patent creates a composite alloy system combining Ni with Al, Si, and V elements in specific proportions, along with optional Cr and Mo additions, to achieve a synergistic effect that produces high magnetic flux density (1.7 T or more) while maintaining cost-effectiveness, overcoming the limitations of conventional electromagnetic steel sheets.
Solution Approach 2:
The patent optimizes the compositional parameters including Ni content (0.1-11.0 mass%), total Al+Si+V content (0.01-10.00 mass%), and controlled Cr+3.3Mo content (≤14 mass%) to achieve the target magnetic flux density of 1.7 T or more, resolving the contradiction between cost and performance.
3Productivity
If high current density is used to reduce equipment size, then the number of coil turns decreases, but excellent soft magnetic characteristics (low coercive force, non-saturated magnetic flux density) are required which are difficult to achieve
Solution Approach 1:
The patent optimizes the alloy composition parameters (Ni: 0.1-11.0 mass%, Al+Si+V: 0.01-10.00 mass%, Cr+3.3Mo: ≤14 mass%) to achieve both high magnetic flux density (1.7 T or more) and low coercive force (1,000 A/m or less), providing excellent soft magnetic characteristics that enable high current density operation with reduced equipment size.
Solution Approach 2:
The patent develops a composite alloy system combining multiple elements (Ni, Al, Si, V, Cr, Mo) in optimized proportions to simultaneously achieve high magnetic flux density and low coercive force, providing the dual performance required for high current density applications with compact size.
Data Source
AI summary
The present invention relates to a soft magnetic alloy containing: Ni, and at least one element selected from the group consisting of Al, Si and V, with the balance being Fe and inevitable impurities, in which, when the content of Ni and the total content of Al, Si and V are expressed by [Ni] and [M], respectively in mass %, and a relationship between [Ni] and [M] is plotted, the coordinate ([Ni], [M]) is present in a region surrounded by the straight lines A, B, C, D, and E.