Soft Magnetic Alloy Powder Spheroidization for Iron Loss Reduction
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Solution Overview
Problem
Soft magnetic alloy powders with high saturation flux density and low coercive force are needed for magnetic application components to reduce iron loss and prevent magnetic saturation, but existing methods result in particles with large coercive force due to shape anisotropy and non-spherical shapes.
Innovation Solution
A soft magnetic alloy powder with a chemical composition of FeaSibBcCdPeCufSngM1hM2i, where M1 includes Co and Ni, and M2 includes Ti, Zr, Hf, Nb, Ta, Mo, W, Cr, Al, Mn, Ag, V, Zn, As, Sb, Bi, and rare earth elements, is produced using a single-roll liquid quenching method and subjected to shear and compressive stresses to achieve a minor-axis length/major-axis length ratio of 0.69 to 1, resulting in spherical particles with favorable coercive force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If Fe-3.5Si soft magnetic alloy powder is used to achieve high saturation flux density, then the magnetic core can operate at high current without saturation, but the coercive force becomes large resulting in high iron loss
Solution Approach 1:
The patent changes the chemical composition parameters by adding specific elements (Ti, Zr, Hf, Nb, Ta, Mo, W, Cr, Al, Mn, Ag, V, Zn, As, Sb, Bi, and rare earth elements) to the Fe-Si-B-C-P-Cu-Sn base alloy system. These compositional modifications enable the material to achieve both high saturation flux density and low coercive force, resolving the contradiction between strength and energy loss.
2Ease of manufacture
If the average minor-axis length/major-axis length ratio of soft magnetic alloy particles is less than 1, then the manufacturing process is simpler, but the magnetic flux concentrates at both ends of the major axis causing magnetic saturation
Solution Approach 1:
The patent explicitly requires that the average minor-axis length/major-axis length ratio of the soft magnetic alloy particles be 0.95 or more, making the particles nearly spherical. This spherical shape prevents magnetic flux concentration at particle ends, eliminating magnetic saturation issues while maintaining ease of manufacture through simple ratio control.
3Loss of energy
If a soft magnetic alloy powder with high space filling rate is used to reduce processing strain, then the coercive force decreases, but achieving spherical particle shape requires complex manufacturing processes
Solution Approach 1:
The patent modifies the chemical composition by adding specific elements that facilitate spherical particle formation during processing. This compositional change enables the material to naturally form spherical particles with high space filling rate, reducing processing strain and coercive force without requiring complex manufacturing processes.
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 resulting soft magnetic alloy powder exhibits reduced magnetic saturation and improved coercive force, leading to lower iron loss in magnetic cores and components, enhancing their performance.
Implementation Method 1
a soft magnetic alloy powder including amorphous particles
Implementation Method 2
subjected to shear and compressive stresses to achieve a minor-axis length/major-axis length ratio of 0.69 to 1
Implementation Method 3
subjected to shear and compressive stresses to achieve a minor-axis length/major-axis length ratio of 0.69 to 1
Implementation Method 4
a soft magnetic alloy powder including amorphous particles... the resulting soft magnetic alloy powder exhibits reduced magnetic saturation and improved coercive force
Data Source
AI summary
A soft magnetic alloy powder includes soft magnetic alloy particles having an amorphous phase. Each of the soft magnetic alloy particles has chemical composition represented by FeaSibBcCdPeCufSngM1hM2i, where M1 is one or more elements of Co and Ni, M2 is one or more elements of Ti, Zr, Hf, Nb, Ta, Mo, W, Cr, Al, Mn, Ag, V, Zn, As, Sb, Bi, Y, and a rare earth element, and 79≤a+h+i≤86, 0≤b≤5, 7.2≤c≤12.2, 0.1≤d≤3, 7.3≤c+d≤13.2, 0.5≤e≤10, 0.4≤f≤2, 0.3≤g≤6, 0≤h≤30, 0≤i≤5, and a+b+c+d+e+f+g+h+i=100 (parts by mol) are satisfied.