MH&W: Magnetec Nanocrystalline Cores

By: Mh&w International  09-12-2011
Keywords: Electronics, Core Losses

Iron-Based nanocrystalline materials have enjoyed increased acceptance in modern electronic designs only in the past few years. Nanocrystalline materials have a proven record of high performance, there has been improved reliability in the manufacturing process and this material is now available from multiple sources.

Nanocrystalline soft magnetic materials are now superior to permalloys, ferrites and even amorphous cobalt based alloys in a growing range of applications. The table below identifies different properties of the various soft magnetic materials that are available today.

Cool Blue for Inverter Drive Motor Systems

Interview with Magnetec's Hans-Joachim Pöss discussing CoolBlue cores and their applications:

Cores for EMI Filters

General Specifications:
Saturation Flux Density 1,200 mT
Permeability
Saturation Magnetostriction < 0.5 ppm
Spec. Electrical Resistivity 115 µΩcm
Density 7.35 g/cm³
Curie Temperature 600°C
Max. Operating Temperature 120°C
Core Losses (100KHz, 300mT, sine wave) > 110 W/kg
Alloy Composition Fe:73.5,Cu:1,Nb:3,Si:15.5,B:7
Nanocrystalline vs. other alloys
Material Alloy
Composition
Strip
Thickness
Losses Saturation
Bsat
Magneto-
striction
Permeability
µm 20KHz 200mT
W/Kg
mT λs
10-6
50Hz
Nanocrystalline Alloys FE 73
(Si,B) 24
20 4 1,200 0.1 20,000-200,000
Standard Crystalline Permalloy Ni 60
Fe 40
50 45 1,200 10 20,000-30,000
Advanced Crystalline Alloy Fe 93.5
Si 6.5
50 40 1,300 0.1 16,000
Amorphous Alloys FE 76
(Si,B) 24
25 18 1,500 25 6,500-8,000
High Performance Ferrite MnZn - 17 50 - 1,000-30,000
Advanced Crystalline Permalloy NI 80
FE 20
30 14 800 1 100,000-300,000
Amorphous Alloy IIa Co 73
(Si,B) 27
25 5 550 < 0.2 100,000-150,000
Amorphous Alloy IIb Co 77
(Si,B) 23
25 6.5 1,000 < 0.2 2,000-4,500
Amorphous Alloy IIc Co 80
(Si,B) 20
25 6.5 1,000 < 0.2 1,000-2,500

Applications

By variation of the annealing parameters, the required properties such as shape of the B/H-Loop and permeability can be adjusted in a wide range (See figure below). As a result, the spectrum of applications in power electronics ranges from chokes and filters to power transformers.

Graph demonstrating the variable range of Hysteresis Loops and Permeability Levels

Benefits

Nanocrystalline over
ferrite or permalloy:

Secondary mainstream
applications:

  1. Significant Reduction of Build Volume of Inductive Component
  2. Less Heat Dissipation due to Reduced Number of Turns
  3. Stable Operation in a Temperature Range of –25 to +120°C.
  4. Larger Safety Margins
  5. Variable Toroidal Geometries—Tooling costs may apply
  1. Power transformers in push-pull converters (full wave) from a few hundred watts to several KW
  2. Trigger transformers for IGBT-driven converters
  3. Current Transformers
  4. Transformers for Passive Earth Leakage Circuit Breakers (Europe primarily)

Keywords: Core Losses, Electronics,

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