Small, lightweight low loss magnetic materials for passive inductors

Opportunities exists to use high moment magnetic nanoparticles CoxFe100-x to replace annealing-stabilized high induction -FeCo phase as the primary phase in the currently used soft magnetic materials (e.g. HITPERM). The key to this development is to design advanced nanocomposites containing high moment nanoparticles for small, lightweight passive inductors, by using an innovative cost-effective chemical approach to obtain high moment, high temperature soft magnetic materials that have low magnetostrictive coefficients and eddy current, and high induction and operating temperature over conventional HITPERM. The proposed project will (1) develop high permeability, large saturation, and induction, low-loss (hysteretic/eddy current) soft magnetic materials including CoFe and CoFe-based ferromagnetic system capable of operating at high temperatures; and (b) improve mechanical properties and corrosion resistance of these materials with weight reduction and performance enhancement at higher operating temperatures by tuning CoFe nanoparticles and enhancing exchange coupling. In this Phase I study, Aegis Technology will develop an inovative class of advanced nanocomposites containing high moment CoFe nanoparticles, and demonstrate an innovative cost-effective approach to produce high permeability, large saturation, and induction, low-loss (hysteretic/eddy current) soft magnetic nanocomposite materials with high operating temperatures. The Phase I research will cover material design, processing development, chracterization and protoyping, with an aim to identify the underlying technical issues that govern the fabrication and performance of this novel class of soft magnetic nanocomposites. The successful development of the high permeability, high induction soft magnetic nanocompsoite materials with low-loss (hysteretic/eddy current) and high operating temperatures will enable the production of high-efficiency small/lightweight passive inductor. This proposed soft magnetic nanocomposite will lay the foundation for next- generation small/lightweight passive inductors that would have much improved magnetic performance in both induction and application temperatures. Applications for these new magnets are expected to include electric power generation and distribution for use in electric drive vehicles, aircraft, space vehicles, and weapons power systems. Higher operating temperature soft magnetic materials would enable simpler, more efficient designs for many military and commercial applications.