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Designing Advanced Soft Magnetic Powder Cores with Ultralow Energy Loss by Combining Ultrasonic and Static

Xiaoying Huang1,2, Dongming Zhu1, Xiao Jin1

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Summary

Ultrasonic vibration-assisted cold pressing (UVP-CP) enhances soft magnetic powder core fabrication. This method improves permeability by 21.0% and reduces core loss by 43.4% for integrated inductors.

Keywords:
amorphoushigh frequencypowder corepowder pressingultrasonic vibration pressing‐cold pressing (UVP‐CP)

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Area of Science:

  • Materials Science
  • Electrical Engineering
  • Powder Metallurgy

Background:

  • Integrated inductors are crucial for miniaturizing electronics and improving power efficiency.
  • Iron-based amorphous/nanocrystalline soft magnetic powders offer desirable magnetic properties but face compaction difficulties due to high strength and brittleness.

Purpose of the Study:

  • To develop a novel fabrication technique for dense soft magnetic powder cores.
  • To overcome the compaction challenges associated with iron-based soft magnetic powders.
  • To enhance the soft magnetic performance of integrated inductors.

Main Methods:

  • Introduction of an ultrasonic vibration-assisted cold pressing (UVP-CP) technique.
  • UVP-CP promotes particle rearrangement and interlocking by reducing interparticle friction.
  • Fabrication of dense powder cores under reduced forming pressure.

Main Results:

  • UVP-CP samples demonstrated significantly improved soft magnetic performance compared to conventional cold pressing.
  • Achieved an effective permeability (µe) of 47.8 at 10 MHz.
  • Reduced core loss to 175.8 mW/cm³ at 50 mT/100 kHz.

Conclusions:

  • The UVP-CP technique enables the fabrication of high-performance integrated inductor cores.
  • Achieved a 21.0% improvement in permeability and a 43.4% reduction in core loss.
  • Establishes a new paradigm for manufacturing advanced soft magnetic cores for power inductors.