Improved Soft Magnetic Materials for High Power Density Electrical Machines

QuesTek proposes to apply its Materials by Designâ technology to the design and development of a new high performance soft magnetic material. Working closely with our OEM partner (Hamilton Sundstrand) and with our research institution collaborator (Northwestern University), we will identify the critical performance criteria for a new high performance soft magnetic material including saturation magnetization, mechanical strength, alloy cost, magnetic hysteresis loses, temperature performance, and electrical resistivity. Property and microstructural models will be developed. Microstructural concepts with the potential of achieving the program goals will be explored, including a novel precipitation-strengthened FeCo alloy concept. A series of prototype alloys that explore different aspects of our modeling- and microstructural concept-spaces will be designed, produced, and tested for mechanical and magnetic performance. In Phase II, Phase I results would be leveraged to design, produce, and test a final alloy composition at intermediate scale and (eventually) full industrial scale. Initial property models would be revisited and refined in Phase II to aid in the final alloy design. 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 DoD platforms for higher power generation and actuator performance. Improved temperature resistance in the new alloy would enable application in hotter environments, including those environments in very close proximity to turbine engine hot zones.