In today's rapidly advancing world, there is an increasing demand for efficient and compact electrical devices. However, traditional magnetic materials used in these devices often fall short of meeting the requirements of modern technology. This is where a soft magnetic composite emerges as a potent solution. With their abilities, they are poised to transform the landscape of electrical engineering.
So, let's take a brief look at these revolutionary materials shaping electrical devices.
What is Soft Magnetic Composite?
Soft Magnetic Composite (SMC) represents a groundbreaking technology poised to revolutionize electrified applications. By encapsulating iron particles with an insulating material, SMCs offer high resistivity and minimal eddy current losses, promising a transformative impact on various industries. By adding an electric current to a carefully designed component made with SMC, an electromagnetic field is created. They are crucial for various applications, such as transformers, alternators, and inductors, where their magnetic properties are essential for efficient operation. According to Extrapolate, the soft magnetic composite market is gaining popularity in various electrified applications, and it is expected to be valued at $42.1 billion by 2030.
What is Hysteresis and its Role in Soft Magnetic Composite?
Hysteresis is the phenomenon where the magnetization of a material lags behind changes in the applied magnetic field. In the case of Soft Magnetic Composites (SMCs), hysteresis plays a vital role in understanding the material's magnetic behavior. The hysteresis loop, which represents the relationship between magnetic flux density and magnetic field strength, illustrates how the material's magnetic properties change with varying fields. SMCs, characterized by smaller and narrower hysteresis loops, are well-suited for applications requiring rapid magnetism reversals and minimal energy dissipation, such as transformers and electromagnets. Understanding hysteresis in SMCs helps engineers optimize the performance and efficiency of devices that undergo rapid magnetic changes or require memory storage capabilities, as it allows for the selection of materials with desirable hysteresis properties for specific applications.
4 Main Types of Soft Magnetic Composite
Take a look at the below-listed 4 examples of SMC:
- Soft Iron: Soft iron is commonly known as a soft magnetic material because it is easily magnetized and demagnetized when introduced to the magnetic field.
- Iron-silicon alloys: Soft magnetic alloys containing iron and silicon are commonly used. These alloys can have different silicon contents, such as 1%, 2%, 4%, and 5% silicon.
- Nickel-iron alloys: Nickel-iron alloys, also known as permeability alloys, are another type of soft magnet. Several types of nickel-iron alloys are used in magnetic applications.
- Soft ferrites: Soft ferrites also known as ceramic magnets are used for the soft magnetic composite cores of transformers and inductors, which have low hysteresis loss and high magnetic permeability.
Potential Applications of Soft Magnetic Composite Applications
SMCs find use in several sectors including
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AC Motors
Soft magnetic composites are used in the design of alternating current (AC) motors. The powder particles are compacted to create the lamination stack for brushless direct current (BLDC) motors.
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Renewable Energy
SMCs have applications in the renewable energy sector, particularly in developing efficient and compact motors for solar power systems. They can be used in off-board power generation, E-pumps, direct current conductors, and compressors.
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Electromobility
With the growing trend toward electrification, SMCs play a crucial role in the shift toward electromobility. They are used in traction motors and other components of electric vehicles, offering minimized eddy current losses, improved efficiency, and superior performance compared to traditional motor cores.
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Rotating Machinery
SMC has become a viable alternative to steel laminations in rotating machinery applications. They offer significantly improved low- and medium-frequency properties, making them suitable for use in rotating machinery, sensors, and fast-switching solenoids.
Recent Advancements in Soft Magnetic Composite
SMCs have seen significant advancements in recent years, driven by the need for improved magnetic materials in various industries. Some key advancements include:
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Multi-Functional Coatings
One area of innovation in SMCs is the development of multi-functional coatings. These coatings are designed to enhance the energetic, electrical, magnetic, and mechanical performances of SMCs. Various coatings can be applied to SMCs, depending on the shape and material of the layer or ferromagnetic powders. fiber-based soft magnetic composites have been developed by coating Fe fibers with a thin polymer layer, yielding materials with exceptional magnetic permeability.
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Developments for Balancing Properties
Researchers are exploring ways to balance high electrical resistivity, high mechanical strength, and high magnetic performance in SMCs. This involves considering the composition of both the core and coating materials or potentially developing new classes of materials.
One such study investigates the preparation of core-shell-structured amorphous SiO2 powders for high-performance SMCs. The process includes phosphating, sodium silicate coating, and annealing. The results show improved permeability and reduced core loss after annealing at 773 K temperature.
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Compact and Powerful Electric Motors
SMC materials have enabled the design of innovative, compact, and powerful electric motors that can be customized to match specific applications. Their ability to allow non-magnetic materials to become magnetic has led to the development of motors. These motors are being used in electric vehicles (EVs), solenoids, relays, and more.
In a Nutshell
Soft magnetic composite materials offer a promising solution for various applications in the fields of electrical engineering and power electronics. They show potential for improved energy efficiency, reduced electromagnetic interference, and compact designs. Innovations like multi-functional coatings, compact yet powerful electric motors, and ongoing research into the balancing properties of SMCs position them as invaluable options for a wide range of applications.
