Reduction of High-Frequency Core Loss of a Fe77.2Si11B8.5Cu0.8Nb2.5 Soft Magnetic Nanocrystalline Alloy by Minor Alloying

doi:10.1007/s40195-024-01729-6

Abstract

Abstract:

Enhancing saturation magnetic flux density (B_s) while reducing high-frequency core loss in Finemet-type nanocrystalline alloys is of great significance in achieving the miniaturization, high-frequency, and energy-saving of modern power electronic devices. In this work, we first designed a high-B_s Fe_77.2Si₁₁B_8.5Cu_0.8Nb_2.5 alloy by appropriately reducing the non-magnetic elements in typical Finemet nanocrystalline alloys, and subsequently alloyed 2 at% Co, Al, and Mo, respectively. The effects of alloying elements on structure and static and high-frequency magnetic properties were studied. The results reveal that, alloying Al or Mo reduces the average α-Fe grain size (D_α-Fe) in the nanocrystalline alloys, while Co exhibits a slight influence. The added Al or Mo results in decreases in both the B_s and coercivity (H_c) of the nanocrystalline alloys, whereas Co increases the B_s without changing H_c, and meanwhile, all alloying elements show minimal effects on effective permeability (μ_e). Furthermore, the addition of Co, Al, or Mo lowers the core loss (P_cv) at 0.2 T/100 kHz of the based nanocrystalline alloy with reductions of 10.9%, 29.6%, and 26.8%, respectively. A Fe_75.2Si₁₁B_8.5Cu_0.8Nb_2.5Al₂ nanocrystalline alloy exhibits outstanding soft magnetic properties with B_s, H_c, μ_e at 10 kHz and 100 kHz, and P_cv at 0.2 T/100 kHz of 1.34 T, 0.8 A/m, 27,400, 18,000, and 350 kW/m³, respectively. The reduction in P_cv is primarily attributed to the decreased eddy current losses, originating from the increased electrical resistivity by elements alloying.

Key words: Fe-based nanocrystalline alloy, Fe-Si-B-Cu-Nb alloy, Soft magnetic property, High-frequency loss, Electrical resistivity

Shushen Guo, Yanhui Li, Yibing Zhang, Lu Yang, Wei Zhang. Reduction of High-Frequency Core Loss of a Fe_77.2Si₁₁B_8.5Cu_0.8Nb_2.5 Soft Magnetic Nanocrystalline Alloy by Minor Alloying[J]. Acta Metallurgica Sinica (English Letters), 2024, 37(11): 1984-1992.

Figures/Tables 8

Fig. 1 XRD patterns a and DSC curves b of melt-spun base and Fe75.2Si11B8.5Cu0.8Nb2.5M2 (M = Co, Al, Mo) alloy ribbons

Table 1 Tx1, ΔT, and Toa of melt-spun base and Fe75.2Si11B8.5Cu0.8Nb2.5M2 alloys, and Dα-Fe, Vα-Fe, Bs, Hc, μe at 10 kHz and 100 kHz, Pcv at 0.2 T/100 kHz, and ρe of the alloys after annealing at Toa

Alloy	T_x1 (K)	ΔT (K)	T_oa (K)	D_α-Fe (nm)	V_α-Fe (%)	B_s (T)	H_c (A/m)	μ_{e, 10 kHz}	μ_{e, 100 kHz}	P_{cv, 0.2 T/100 kHz} (kW/m³)	ρ_e (μΩ cm)
Base alloy	756	175	863	14.3 ± 0.4	66.2 ± 2.0	1.43 ± 0.01	2.5 ± 0.5	27,100	18,000	497 ± 10.6	100 ± 1.0
M = Co	760	183	833	14.7 ± 0.6	68.2 ± 3.1	1.48 ± 0.02	2.2 ± 0.7	27,600	16,800	443 ± 12.3	106 ± 1.6
M = Al	760	188	833	10.4 ± 0.3	63.0 ± 2.2	1.34 ± 0.01	0.8 ± 0.3	27,400	18,000	350 ± 8.5	114 ± 2.3
M = Mo	783	191	863	10.2 ± 0.5	64.6 ± 1.9	1.30 ± 0.01	1.0 ± 0.2	26,700	17,200	364 ± 15.2	115 ± 3.2

Fig. 2 Changes in Bs and Hc of base and Fe75.2Si11B8.5Cu0.8Nb2.5M2 (M = Co, Al, Mo) alloy ribbons as a function of Ta a, Bs, Hc b and frequency dependence of μe c of the alloys after annealing at Toa

Fig. 3 Frequency a and maximum external field b dependences of Pcv of base and Fe75.2Si11B8.5Cu0.8Nb2.5M2 (M = Co, Al, Mo) alloy cores after annealing at Toa. Inset in b shows the fitting exponent c

Fig. 4 XRD patterns (right showing partially enlarged peaks with fitting curves) a, Dα-Fe and Vα-Fe b of base and Fe75.2Si11B8.5Cu0.8Nb2.5M2 (M = Co, Al, Mo) alloys after annealing at Toa

Fig. 5 Bright-field TEM images inset with corresponding SAED patterns and grain size distributions with normal fitting a-d and high-resolution TEM images e, f of base and Fe75.2Si11B8.5Cu0.8Nb2.5M2 (M = Co, Al, Mo) alloys after annealing at Toa. a, e Base alloy; b M = Co; c, f M = Al; d M = Mo

Fig. 6 Frequency dependences of separated losses of base alloy a, and separated Pec b and Pex c of base and Fe75.2Si11B8.5Cu0.8Nb2.5M2 alloy (M = Co, Al, Mo) alloy cores after annealing at Toa

Fig. 7 Electrical resistivity of based and Fe75.2Si11B8.5Cu0.8Nb2.5M2 (M = Co, Al, Mo) alloys in melt-spun and annealed states along with calculated resistivity for α-Fe a, δ, ΔHmix, and Sconf b, and comparison of Pec, Ptot, and ρe of the nanocrystalline alloys c

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Reduction of High-Frequency Core Loss of a Fe_77.2Si₁₁B_8.5Cu_0.8Nb_2.5 Soft Magnetic Nanocrystalline Alloy by Minor Alloying

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