Soft Magnetic Alloy Powder Composition for Low Coercivity
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Solution Overview
Problem
Existing soft magnetic alloy powders fail to achieve low coercivity and high permeability, which are essential for efficient magnetic applications, due to limitations in particle size distribution and composition.
Innovation Solution
A soft magnetic alloy powder with a specific compositional formula (Fe(1−(α+β))X1αX2β)(1−(a+b+c+d+e+f)) is developed, where X1 includes Co and Ni, X2 includes Al, Mn, and rare earth elements, and M includes Nb, Hf, and V, with controlled amounts of elements to achieve a high amorphous ratio and optimized particle size and circularity, resulting in low coercivity and high permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional soft magnetic alloy powders are used, then manufacturing is simpler, but coercivity is high and permeability is low
Solution Approach 1:
The patent applies parameter changes by precisely controlling the compositional parameters (elements M, B, P, Si, C, S and their ratios) and processing parameters (particle size distribution, circularity) to achieve the desired magnetic properties. The specific compositional formula with defined ranges for each element and the requirement for high amorphous ratio (85% or more) represent parameter optimization to resolve the contradiction between manufacturing simplicity and magnetic performance.
Solution Approach 2:
The patent employs composite materials by creating a multi-element alloy system combining Fe with Co/Ni, Al/Mn/rare earth elements, and transition metals (Nb, Hf, Zr, Ta, Mo, W, Ti, V), along with controlled amounts of B, P, Si, C, and S. This complex composite composition enables achievement of low coercivity and high permeability that cannot be obtained with conventional simpler alloys.
2Reliability
If particle size is reduced to increase packing density, then permeability improves, but particle shape irregularity increases
Solution Approach 1:
The patent applies parameter changes by specifying both particle size parameters (D50, size ranges for different particle populations) and shape parameters (average circularity requirements) to simultaneously achieve high packing density and good magnetic performance. The controlled particle size distribution with specific circularity requirements resolves the contradiction between permeability improvement through size reduction and manufacturing precision maintenance.
Data Source
AI summary
A soft magnetic alloy powder which is a soft magnetic alloy powder having a low coercivity, and with which it is possible to obtain a green compact magnetic core having a high magnetic permeability. A soft magnetic alloy powder including a composition formula (Fe(1−(α+β))X1 αX2 β) (1−(a+b+c+d+e+f)) MaBbPcSidCeSf. XI is one or more elements selected from the group consisting of Co and Ni, X2 is one or more elements selected from the group consisting or Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O and rare earth elements, and M is one or more elements selected from the group consisting of Nb, Hf, Zr, Ta, Mo, W, Ti and V. The amount of each component contained is within a specified range. The amorphous rate X (%) is at least 85%.