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<p>Soft magnetic materials are critical for bulk/large cores in transformers and motors, and yet achieving uniform properties in industrial-scale devices remains challenging. This study develops a one-step, low heating rate annealing process to achieve uniform fine α-Fe nanocrystallization (grain size &lt; 20 nm) across the entire volume of Fe<sub>81.5</sub>Si<sub>0.5</sub>B<sub>4.5</sub>P<sub>11</sub>Cu<sub>0.5</sub>C<sub>2</sub> bulk toroidal cores. The proposed process effectively eliminates microstructural heterogeneity induced by crystallization dynamics and temperature gradients. At the same time, it achieves a high magnetic flux density (<i>B</i><sub>80</sub>) of ∼169 emu/g, low coercivity of ∼5.4 A/m, and low core loss of <i>W</i><sub>1.0/50</sub> = 0.12 W/kg and <i>W</i><sub>1.5/50</sub> = 0.31 W/kg. The permeability remains constant at a value greater than 4.5×10<sup>3</sup> up to a frequency of 4×10<sup>4</sup> Hz. This research provides a scalable solution for the industrial-scale production of high-performance nanocrystalline magnetic cores, advancing the development of next-generation power electronic devices.</p>

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Excellent soft magnetic Fe-based nanocrystalline bulk toroidal cores via one-step low-heating-rate annealing

  • 期刊论文

  • 发表日期：

    2025年5月27日

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  • Yanan Chen,
  • Xing Tong,
  • Yuanfei Cai,
  • Yaocen Wang,
  • Meng Gao,
  • Haibo Ke,
  • Guangqiang Zhang,
  • Haiyang Bai,
  • Weihua Wang,
  • Juntao Huo,
  • Jun-Qiang Wang,
  • Yan Zhang

摘要

Soft magnetic materials are critical for bulk/large cores in transformers and motors, and yet achieving uniform properties in industrial-scale devices remains challenging. This study develops a one-step, low heating rate annealing process to achieve uniform fine α-Fe nanocrystallization (grain size < 20 nm) across the entire volume of Fe81.5Si0.5B4.5P11Cu0.5C2 bulk toroidal cores. The proposed process effectively eliminates microstructural heterogeneity induced by crystallization dynamics and temperature gradients. At the same time, it achieves a high magnetic flux density (B80) of ∼169 emu/g, low coercivity of ∼5.4 A/m, and low core loss of W1.0/50 = 0.12 W/kg and W1.5/50 = 0.31 W/kg. The permeability remains constant at a value greater than 4.5×103 up to a frequency of 4×104 Hz. This research provides a scalable solution for the industrial-scale production of high-performance nanocrystalline magnetic cores, advancing the development of next-generation power electronic devices.