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Metals
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Soft Magnetic Composites: Manufacture, Properties and Applications
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Soft Magnetic Composites: Manufacture, Properties and Applications

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metallic Functional Materials".

Deadline for manuscript submissions: closed (30 June 2024) | Viewed by 6504

Special Issue Editor

Dr. Xuebin Zhang

E-Mail Website
Guest Editor
School of Materials Science and Engineering, Hefei University of Technology, Hefei 230009, China
Interests: magnetic material; metal matrix/ceramic matrix composites; porous ceramics and ceramic membranes

Special Issue Information

Dear Colleagues,

During the past three decades, most of the effort in magnetic composites has focused on the development of powder cores, also known as soft magnetic composites (SMCs). SMCs have been constructed of micrometer-scale particles (most often Fe but sometimes alloys such as Fe-Si-Al, Fe-Si, or Fe-Ni), which appears to be a feasible concept to be applied in strategic topics for modern society, including sensing, energy generation, and conversion. With a unique freedom regarding material selection based on powder metallurgy techniques, this class of engineering magnetic materials allows novel designs able to drive operation conditions to new limits, unlocking the potential of novel applications. The Special Issue will comprise articles on soft magnetic composites regarding their manufacture, magnetic performance, applications, and future trends.  Manuscripts will be welcomed from both fundamental scientific researchers and authors belonging to industrial companies involved in the field.

Dr. Xuebin Zhang
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • soft magnetic composites
  • core loss
  • permeability
  • magnetic properties
  • DC bias performance
  • coating layers

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Published Papers (5 papers)

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Research

16 pages, 11406 KiB  
Article
A Study on Powder Metallurgy Process for x Electric Vehicle Stator Core
by Jaemin Kim and Seonbong Lee
Metals 2024, 14(8), 858; https://doi.org/10.3390/met14080858 - 26 Jul 2024
Viewed by 871
Abstract
The powder metallurgy process of manufacturing the motor core and inductor core using SMC greatly changes formability depending on the process variables. Therefore, this study explored the optimal process conditions of the powder metallurgy of the SMC stator core using Fe-6.5 wt.%Si by [...] Read more.
The powder metallurgy process of manufacturing the motor core and inductor core using SMC greatly changes formability depending on the process variables. Therefore, this study explored the optimal process conditions of the powder metallurgy of the SMC stator core using Fe-6.5 wt.%Si by applying the Taguchi method, and selected deviations between the maximum and minimum relative densities as characteristic values; selected the formation pressure, molding temperature, and heating time as control factors; and derived the process conditions with the maximum SNR. As a result, the molding pressure was 120 MPa, the molding temperature was 500 °C, and the heating time was 120 s, and the material properties of the electrical properties’ core loss, saturation flux density, and bulk conductivity were measured and analyzed. After that, a prototype was produced, the analysis was verified, the mechanical properties were verified by performing density and SEM analysis at 15, 9, and 3 mm points based on the press vertical direction, and a motor was manufactured to verify the electrical properties. Full article
(This article belongs to the Special Issue Soft Magnetic Composites: Manufacture, Properties and Applications)
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19 pages, 9281 KiB  
Article
A Study on the Optimal Powder Metallurgy Process to Obtain Suitable Material Properties of Soft Magnetic Composite Materials for Electric Vehicles
by Seongsu Kang and Seonbong Lee
Metals 2024, 14(7), 815; https://doi.org/10.3390/met14070815 - 15 Jul 2024
Cited by 1 | Viewed by 1151
Abstract
This study systematically investigates the impact of the material properties of soft magnetic composites (SMCs) on the powder metallurgy forming process. It proposes a suitable material selection process for various motor types and shapes and determines the optimal forming conditions for each SMC [...] Read more.
This study systematically investigates the impact of the material properties of soft magnetic composites (SMCs) on the powder metallurgy forming process. It proposes a suitable material selection process for various motor types and shapes and determines the optimal forming conditions for each SMC material. This study employed the Taguchi design method to identify key control factors such as powder type, forming temperature, and forming speed, and analyzed their effects on relative density. Simulation results indicated that AncorLam HR exhibited superior properties compared with AncorLam and Fe-6.5wt.%Si. The optimal conditions determined through signal-to-noise ratio (SNR) calculations were AncorLam HR at 60 °C and five cycles per minute (CPMs). Validation through simulation and SEM analysis confirmed improved density uniformity and reduced defects in products formed under optimal conditions. Final prototype testing demonstrated that the selected conditions achieved the target density with minimal variance, enhancing the mechanical properties and performance of the motors. These results suggest that the appropriate application of SMC materials can significantly enhance motor efficiency and reliability. Full article
(This article belongs to the Special Issue Soft Magnetic Composites: Manufacture, Properties and Applications)
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14 pages, 7394 KiB  
Article
Effect of Gradient Heat Conduction on Secondary Recrystallization of Grain-Oriented Silicon Steel
by Qian Gao, Xianhui Wang, Jun Li, Laifu Cao, Jian Gong and Bo Li
Metals 2024, 14(2), 152; https://doi.org/10.3390/met14020152 - 26 Jan 2024
Viewed by 1064
Abstract
The grain-oriented silicon steels were subjected to gradient heat conduction during high-temperature annealing by using thermal insulation cotton. The macrostructures of samples subjected to circumferential gradient heat conduction showed a “petal-like” morphology with peripheral columnar grains and central equiaxed grains, while samples subjected [...] Read more.
The grain-oriented silicon steels were subjected to gradient heat conduction during high-temperature annealing by using thermal insulation cotton. The macrostructures of samples subjected to circumferential gradient heat conduction showed a “petal-like” morphology with peripheral columnar grains and central equiaxed grains, while samples subjected to transverse gradient heat conduction showed a morphology with approximately 50% columnar grains and 50% equiaxed grains. The grain orientations, magnetic domains as well as magnetic properties in different regions were detected. Results showed that the magnetic induction intensity of cylindrical grains was better than that of equiaxed grains while the iron loss was worse, which indicated that a fast heating rate during high-temperature annealing was conducive to the accuracy of Goss grains. The magnetic domains in columnar grains were wider than the equiaxed grains, which resulted in poorer iron loss. A theory of the competitive growth among secondary Goss grains was proposed. Under the condition of gradient heat conduction, once the Goss grains with the fastest heat conduction grew up abnormally, they would compete with other Goss grains which were supposed to survive in traditional processes and swallow up them until adjacent to the secondary equiaxed grains which were later developed. Full article
(This article belongs to the Special Issue Soft Magnetic Composites: Manufacture, Properties and Applications)
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14 pages, 4151 KiB  
Article
Improved Anti-Saturation Performance of Fe-Si-Al Soft Magnetic Powder Core via Adjusting the Alloy Composition
by Bowei Zhang, Zhongqiu Zou, Xuebin Zhang, Yu Han, Wei Liu and Hailin Su
Metals 2024, 14(1), 107; https://doi.org/10.3390/met14010107 - 16 Jan 2024
Viewed by 1602
Abstract
Ball-milled Fe-Si-Al soft magnetic powder cores with the particle compositions away from the classical Sendust point were prepared in this work. The influences of alloy composition on the metallographic structure, density, hardness, and resistivity of Fe-Si-Al alloy, as well as the frequency-dependent permeability, [...] Read more.
Ball-milled Fe-Si-Al soft magnetic powder cores with the particle compositions away from the classical Sendust point were prepared in this work. The influences of alloy composition on the metallographic structure, density, hardness, and resistivity of Fe-Si-Al alloy, as well as the frequency-dependent permeability, loss, and the anti-saturation performance of Fe-Si-Al powder cores, were investigated systematically. It was found that the hardness of Fe-Si-Al alloy increases with the Si mass ratio and the saturation magnetization (Ms) increases with the Fe mass ratio. The alloy hardness affects the particle size after the ball-milling process and, thus, influences the porosity of the powder core. Together with adjusting the demagnetization field by controlling the particle size and the core’s porosity, changing the alloy composition to drive K and λ deviating from zero can effectively improve the anti-saturation performance of Fe-Si-Al powder cores at the expense of hysteresis loss, to some extent. In this work, good comprehensive magnetic properties were obtained in the Fe85.5-Si12-Al2.5 powder core. Its effective permeability percentage at 100 Oe and Ms were 59.12% and 132.23 emu/g, respectively, which are higher than those of the classical Sendust core. This work provides a feasible idea for optimizing the overall performance of the high-power magnetic device. Full article
(This article belongs to the Special Issue Soft Magnetic Composites: Manufacture, Properties and Applications)
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12 pages, 7423 KiB  
Article
Effects of Stress on Loss and Magnetic Properties of Fe80Co3Si3B10P1C3 Amorphous Iron Cores
by Wei Zheng, Guangqiang Zhang, Qian Zhang, Haichen Yu, Zongzhen Li, Su Song, Mingyu Gu, Shaoxiong Zhou and Xuanhui Qu
Metals 2023, 13(11), 1823; https://doi.org/10.3390/met13111823 - 29 Oct 2023
Viewed by 1352
Abstract
The research on how to reduce energy consumption and improve the efficiency of amorphous motors has extensive coverage. This study systematically investigates the influence of internal stress induced by impregnation curing and interference fit on the soft magnetic properties and loss characteristics of [...] Read more.
The research on how to reduce energy consumption and improve the efficiency of amorphous motors has extensive coverage. This study systematically investigates the influence of internal stress induced by impregnation curing and interference fit on the soft magnetic properties and loss characteristics of Fe80Co3Si3B10P1C3 (CAF4) amorphous alloy iron cores. The amorphous iron core samples undergo analysis through differential scanning calorimetry (DSC), transmission electron microscopy (TEM), X-ray diffraction (XRD), magnetic performance testing equipment, flexible pressure sensors, and magnetostriction testers. The CAF4 amorphous iron core after impregnation curing (AIC) exhibits the lowest loss of P1.2T,1.5 kHz = 22.8 W/kg when annealed at 260 °C, representing a 21% increase compared to the pre-impregnation curing (BIC) state. Within the commonly utilized interference fit range, the loss growth rate of CAF4 amorphous iron cores is lower than that of Fe80Si9B11 (1K101). Likewise, at a frequency of 50 Hz and an excitation of 1000 A/m, the magnetostriction coefficient of CAF4 is smaller than that of 1K101. Within the typical interference fit range, the magnetization performance of CAF4 amorphous iron cores surpasses that of 1K101, favoring lightweight and compact motor designs and reducing copper losses. Consequently, CAF4 amorphous iron cores exhibit significant advantages when employed in motors. Full article
(This article belongs to the Special Issue Soft Magnetic Composites: Manufacture, Properties and Applications)
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