Soft Magnetic Powder Composition for Permeability and Insulation
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Solution Overview
Problem
Existing iron-based soft magnetic alloy powders face challenges in maintaining high magnetic permeability and withstand voltage due to the addition of elements like Al and Ca, which deteriorate magnetic properties and reduce insulation between particles.
Innovation Solution
A soft magnetic powder composition with Fe as the main component, Si content between 2.5% and 6.5%, Cr content between 1.0% and 10.0%, and S content between 0.0020% and 0.0070%, optimized oxygen content, and specific surface area ratio, which enhances magnetic permeability and withstand voltage by reducing oxide occupancy and improving particle insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If Al and Ca are added to reduce oxygen content, then oxygen content decreases, but magnetic properties deteriorate and insulation between particles decreases
Solution Approach 1:
The patent changes the chemical composition parameters by replacing Al and Ca with a specific combination of Si (2.5-6.5 mass%), Cr (1.0-10.0 mass%), and S (0.0020-0.0070 mass%). This parameter change achieves oxygen reduction while maintaining magnetic properties and particle insulation, as evidenced by the optimized magnetic permeability and withstand voltage in the resulting soft magnetic powder.
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 optimized composition achieves a green compact with excellent magnetic properties and high withstand voltage, preventing eddy current loss and ensuring high filling properties during compaction.
Implementation Method 1
high magnetic permeability is achieved in a magnetic element having a dust core
Implementation Method 2
preventing eddy current loss
Data Source
AI summary
A soft magnetic powder contains: Fe as a main component; Si having a content of 2.5 mass % or more and 6.5 mass % or less; Cr having a content of 1.0 mass % or more and 10.0 mass % or less; S having a content of 0.0020 mass % or more and 0.0070 mass % or less; and impurities. A ratio A/B is 3000 or more and 8000 or less, where A [ppm] is an oxygen content in terms of mass ratio and B [m2/g] is a specific surface area.