Soft Magnetic Powder Composition for Low Loss and High Resistivity
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Solution Overview
Problem
Current soft magnetic powders lack both excellent soft magnetic characteristics and high powder resistance, which are essential for reducing energy loss and increasing efficiency in electronic and communication equipment.
Innovation Solution
A soft magnetic powder with a specific composition formula (Fe(1−(α+β))X1αX2β)(1−(a+b+c+d+e+f))MaBbPcSidCeSf, where X1 includes Co and Ni, X2 includes Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, and rare earth elements, and M includes Nb, Hf, Zr, Ta, Mo, W, Ti, V, with controlled content ratios and oxygen content between 300 ppm to 3,000 ppm, forming an amorphous phase with nanohetero structure and Fe-based nanocrystals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional soft magnetic powders are used, then good soft magnetic characteristics can be achieved, but powder resistance is insufficient
Solution Approach 1:
The invention changes the chemical composition parameters by introducing specific elements (Co: 0.1-5 at%, Ni: 0.1-5 at%, Al: 0.1-5 at%, Mn: 0.1-5 at%, Cu: 0.1-5 at%, Cr: 0.1-5 at%, Nb: 0.1-5 at%, Hf: 0.1-5 at%, Zr: 0.1-5 at%, Ti: 0.1-5 at%, V: 0.1-5 at%) and controlling oxygen content (300-3000 ppm) to simultaneously improve soft magnetic characteristics and powder resistance
Solution Approach 2:
The invention creates a composite amorphous alloy system combining Fe with multiple other elements (Co, Ni, Al, Mn, Cu, Cr, Nb, Hf, Zr, Ti, V, B, Si, P, C, S) to achieve both good soft magnetic characteristics and high powder resistance that cannot be obtained with single-element additions
2Reliability
If Fe-B-M based soft magnetic amorphous alloy is used, then high saturation magnetic flux density is achieved, but powder resistance remains insufficient
Solution Approach 1:
The invention extends the Fe-B-M amorphous alloy system by adding multiple other elements (Co, Ni, Al, Mn, Cu, Cr, Nb, Hf, Zr, Ti, V, and others) to create a multi-element composite amorphous alloy that simultaneously achieves high saturation magnetic flux density and high powder resistance
Solution Approach 2:
The invention modifies the alloy composition parameters by adding specific ranges of multiple elements and controlling oxygen content to transform the Fe-B-M alloy into a high-performance soft magnetic powder with improved powder resistance while maintaining high saturation magnetic flux density
Data Source
AI summary
Disclosed is a soft magnetic powder including a main component represented by composition formula: (Fe(1−(α+β))X1αX2β)(1−(a+b+c+d+e+f))MaBbPcSidCeSf. X1 represents one or more selected from the group consisting of Co and Ni; X2 represents one or more selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, and rare earth elements; and M represents one or more selected from the group consisting of Nb, Hf, Zr, Ta, Mo, W, Ti, and V. The following relations are satisfied: 0≤a≤0.140; 0.020<b≤0.200; 0<c≤0.150; 0≤d≤0.060; 0≤e≤0.030; 0≤f≤0.010; α≥0; β≥0; and 0≤α+β≤0.50. An oxygen content ratio in the soft magnetic powder is from 300 ppm to 3,000 ppm as a mass ratio.