Improved Soft Magnetic Materials for High Power Density Electrical Machines

In this proposed Phase II STTR program, QuesTek will apply its Materials by Design(TM) technology to the continued development of new high performance soft magnetic alloys. Working closely with the Air Force, with our OEM partner (Hamilton Sundstrand) and with our STTR research institution collaborator (Northwestern University), we have identified the critical performance criteria for new high performance soft magnetic materials including saturation magnetization, mechanical strength, alloy cost, magnetic hysteresis loses, temperature performance, and electrical resistivity. In Phase I, a series of prototype alloys that explore different aspects of our modeling and microstructural concept spaces were designed, produced at button scale, and tested for mechanical and magnetic performance. The results demonstrated the feasibility of QuesTek’s alloy concepts, with observed improvements in alloy strength without a detriment in magnetic performance. In Phase II, Phase I results will be leveraged to design, produce, process and test a final alloy composition at intermediate scale and, eventually, full industrial scale and final product form (rolled strip). BENEFIT: The need for high performance soft magnetic alloys with improved strength, magnetization, and temperature capabilities is prevalent in numerous electrical motor and actuator applications, aerospace and otherwise. A high performance soft magnetic alloy with improved mechanical and magnetic properties could directly address requirements on Air Force and DoD platforms for higher power generation and actuator performance. New soft magnetic materials with increased strength, at the same magnetic performance, could lead to a reduction in power system size and weight, and, ultimately, to an improvement in electrical efficiency.