Near net shape fabrication of anisotropic Fe-6.5%Si soft magnetic materials

Ouyang, Gaoyuan; Jensen, Brandt; Tang, Wei; Schlagel, Jordan; Hilliard, Benjamin; Pan, Chaochao; Cui, Baozhi; Dennis, Kevin; Jiles, David; Monson, Todd; Anderson, Iver; Kramer, Matthew J.; Cui, Jun

doi:10.1016/j.actamat.2020.09.084

Title: Near net shape fabrication of anisotropic Fe-6.5%Si soft magnetic materials

Journal Article · Tue Dec 01 00:00:00 EST 2020 · Acta Materialia

DOI:https://doi.org/10.1016/j.actamat.2020.09.084· OSTI ID:1682373

Ouyang, Gaoyuan; Jensen, Brandt; Tang, Wei; Schlagel, Jordan; Hilliard, Benjamin; Pan, Chaochao; Cui, Baozhi; Dennis, Kevin; Jiles, David;

; Anderson, Iver; Kramer, Matthew J.; Cui, Jun

Efficient and cost-effective soft magnetic materials (SMMs) are essential for accelerating the adoption of electric vehicles and the sustainable growth of renewable electricity. While amorphous and nanocrystalline SMMs offer remarkably low magnetic losses, their poor mechanical properties, limited availability in size and shape (particularly ribbon widths), and high cost prevent them from widespread industrial application. Here, we show that ductile Fe-6.5%Si 2-D flakes could be used as building blocks for making high performance bulk SMMs. This approach bypasses the brittleness problem and creates a new morphology and a new fabrication method for the SMMs with improved energy efficiency and lower processing cost. Ductile Fe-6.5%Si flakes are mass-produced by melt spinning and are then consolidated to bulk SMMs with a brick-wall type of structure. The novel process introduces anisotropic electrical and magnetic properties and enables near net shape processing. Resulting Fe-6.5%Si thin sheets display low iron loss (W10/400 = 6.1 W/kg) and high permeability (µ_r = 28,000), which are comparable to the current state of the art high silicon steel. CaF₂ coating reduces the iron losses for thick Fe-6.5%Si parts. Polymer coated Fe-6.5%Si flake cores show potential for high power inductors with greater permeability and lower losses than traditional powder cores.

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Research Organization:: Ames Laboratory (AMES), Ames, IA (United States); Iowa State Univ., Ames, IA (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Transportation Office. Vehicle Technologies Office; USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC02-07CH11358; EE0007794; NA0003525

OSTI ID:: 1682373

Alternate ID(s):: OSTI ID: 1688773; OSTI ID: 1864010

Report Number(s):: IS-J-10,341; S1359645420307874; PII: S1359645420307874

Journal Information:: Acta Materialia, Journal Name: Acta Materialia Vol. 201 Journal Issue: C; ISSN 1359-6454

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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