Power Dense, High Temperature Stable Inductors for Electrified Vehicles with Permeability Engineered Metal Amorphous Nanocomposite Alloys

Electrification trends across the Air Force mission space have increased demand for high power, highly efficient, and power dense electrical energy conversion. Magnetic cores and components (transformers, inductors, rotor / stator) serve a critical function in power electronics (PE) based converters and motors / generators, but tend to be the bulkiest components, particularly for megawatt (MW)-class applications as in emerging hybrid-electric propulsion drive and control systems.  Co-based MANC alloys have been demonstrated to show unprecedented temperature stability of microstructure, magnetic properties, and permeability up to ~400-500oC, far surpassing capabilities of commercial MANC, ferrite, and metallic powder core materials limited to ~150oC.  Advanced processing methods combining in-line and magnetic field processing have also yielded ~2-10x improvements in core loss compared to commercial powder cores. High temperature stability, low-losses, high linearity, and tunable permeability of in-line processed Co-based MANC alloys yield size, weight, and efficiency improvements with passive thermal management for improved reliability. The proposed program seeks to exploit novel patented Co-based MANC alloy and in-line processing technology, in conjunction with state of art high temperature windings, packaging, and insulation strategies, to design, develop, and demonstrate unprecedented performance of high value, high temperature, and power dense inductors for hybrid-electric propulsion and other Air Force power electronics applications. During Phase I, detailed specifications will be provided by industry partner Raytheon Technologies (RTX) for at least two high temperature filter inductors for Air Force aviation applications, and both preliminary and detailed designs of inductors will be completed by CorePower Magnetics in preparation for inductor fabrication, testing, and performance benchmarking to commence during Phase II. RTX will provide the team with industrial perspective, and collaborations with NASA Glenn Research Center, a joint developer of underlying CorePower Magnetics materials and manufacturing technology, will provide the team with access to additional technical capabilities, expertise, and material performance characteristics. Commercialization efforts will develop a technology roadmap and commercialization pathway for inductor technologies to be pursued with detailed specifications and estimated pricing for Air Force power conversion. Phase I will pave the way for Phase II efforts focused on scaled prototype manufacturing, testing, and performance benchmarking of inductor technology in collaboration with partners from lab to pilot scale and ultimately low-volume commercial demonstrations.