Soft Magnetic Alloy Powder Composition for Low Coercivity
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Solution Overview
Problem
Existing soft magnetic alloy powders do not adequately address the need for improved sphericity and reduced coercivity in compositions different from those disclosed in Patent Document 1, limiting their effectiveness in reducing energy loss and improving power supply efficiency.
Innovation Solution
A soft magnetic alloy powder with a composition of (Fe(1−(α+β))X1αX2β)(1−(a+b+c+d+e+f))MaBbPcSidCeSf, where X1 and X2 are specific elements, and M is a group of metals, is formulated to achieve low coercivity and high sphericity, with controlled contents of B, S, and other elements to prevent crystal growth and enhance amorphousness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional soft magnetic alloy compositions are used, then manufacturing is simpler, but sphericity and coercivity performance are insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition ratios of multiple elements (Fe, Co, Ni, Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O, rare earth elements, Nb, Hf, Zr, Ta, Mo, W, Ti, V, B, P, Si, C, S) within specific ranges. This compositional parameter optimization achieves high sphericity (0.90 or more) and low coercivity (3.0 Oe or less) while maintaining manufacturability through defined composition boundaries.
Solution Approach 2:
The patent employs composite materials by combining multiple metallic elements in a specific alloy formulation. The soft magnetic alloy powder integrates Fe-based matrix with controlled additions of Co, Ni, Al, Mn, and other elements, creating a composite structure that simultaneously improves sphericity, reduces coercivity, and enables nanocrystal formation for enhanced magnetic properties.
2Manufacturing precision
If element contents are increased to improve magnetic characteristics, then coercivity decreases, but crystal growth occurs reducing amorphousness
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition ratios of multiple elements (Fe, Co, Ni, Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O, rare earth elements, Nb, Hf, Zr, Ta, Mo, W, Ti, V, B, P, Si, C, S) within specific ranges. This compositional parameter optimization achieves high sphericity (0.90 or more) and low coercivity (3.0 Oe or less) while maintaining manufacturability through defined composition boundaries.
Solution Approach 2:
The patent applies local quality by creating a dual-phase structure with amorphous matrix regions and controlled nanocrystal regions. The composition is designed so that B, P, Si, C, and S elements locally suppress crystal growth in the matrix while allowing controlled nanocrystal formation, achieving low coercivity through this heterogeneous local structure rather than uniform composition.
3Quantity of substance
If sphericity is improved by composition optimization, then filling rate increases, but coercivity reduction is insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition ratios of multiple elements (Fe, Co, Ni, Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O, rare earth elements, Nb, Hf, Zr, Ta, Mo, W, Ti, V, B, P, Si, C, S) within specific ranges. This compositional parameter optimization achieves high sphericity (0.90 or more) and low coercivity (3.0 Oe or less) while maintaining manufacturability through defined composition boundaries.
Solution Approach 2:
The patent employs composite materials by combining multiple metallic elements in a specific alloy formulation. The soft magnetic alloy powder integrates Fe-based matrix with controlled additions of Co, Ni, Al, Mn, and other elements, creating a composite structure that simultaneously improves sphericity, reduces coercivity, and enables nanocrystal formation for enhanced magnetic properties.
Data Source
AI summary
A soft magnetic alloy powder includes a main component of (Fe(1−(α+β))X1αX2β)(1−(a+b+c+d+e+f))MaBbPcSidCeSf, in which X1 is one or more of Co and Ni, X2 is one or more of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O, and rare earth elements, and M is one or more of Nb, Hf, Zr, Ta, Mo, W, Ti, and V. 0≤a≤0.160, 0.020≤b≤0.200, 0≤c≤0.150, 0≤d≤0.060, 0≤e≤0.030, 0.0010≤f≤0.030, 0.005≤f/b≤1.50, α≥0, β≥0, and 0≥α+β≥0.50 are satisfied.