Metglas, Inc.

Hitachi Metals, Ltd.

Eric Theisen

Yuichi Ogawa

Ryusuke Hasegawa

Daichi Azuma

William Coughlan

Yuji Matsumoto

Donald Robert Reed, Jr

James Perrozi

Ronald Joseph Martis

Naoki Ito

John Paul Webb

Donald E Granger, Jr

Thomas Joseph Hastie

The invention relates to the reduction of core losses in soft magnetic applications utilizing amorphous foil as the core material. Amorphous foil is known to have lower losses when compared to crystalline silicon steel laminations. It is found that a reduction of 10-40% of losses can be achieved over the current state of the art amorphous material by mechanical scribing of the surface of the soft magnetic laminations comprising the wound core in power conditioning devices such as a transformer. The scribing process introduces control of the magnetic domains causing ease of magnetic flux reversal

Process for in-line mechanically scribing of amorphous foil for magnetic domain alignment and core loss reduction

An Fe&#x2014;Si&#x2014;B&#x2014;C-based amorphous alloy ribbon as thick as 20-30 &#x3bc;m having a composition comprising 80.0-80.7 atomic % of Fe, 6.1-7.99 atomic % of Si, and 11.5-13.2 atomic % of B, the total amount of Fe, Si and B being 100 atomic %, and further comprising 0.2-0.45 atomic % of C per 100 atomic % of the total amount of Fe, Si and B, except for inevitable impurities has a stress relief degree of 92% or more.

Fe&#x2014;Si&#x2014;B&#x2014;C-based amorphous alloy ribbon and transformer core formed thereby

An iron-based soft magnetic alloy greater than 63.5 mm in width, a thickness between 13 and 20 microns and having a composition represented by the following formula:(FeM)CuSiBM'M&#x2033;Xwherein M is Co and/or Ni, M&#x2032; is at least one element selected from the group consisting of Nb, W, Ta, Zr, Hf, Ti and Mo, M&#x2033; is at least one element selected from the group consisting of V, Cr, Mn, Al, elements in the platinum group, Sc, Y, rare earth elements, Au, Zn, Sn and Re, X is at least one element selected from the group consisting of C, Ge, P, Ga, Sb, In, Be and As, and a, x, y, z, p, q and r respectively satisfy 0&#x2264;a&#x2264;0.5, 0.1&#x2264;x&#x2264;3, 0&#x2264;y&#x2264;30, 1&#x2264;z&#x2264;25, 5&#x2264;y+z&#x2264;30, 0.1&#x2264;p&#x2264;30, q&#x2264;10 and r&#x2264;10, the alloy being at least 50% crystalline with an average particle size of 100 nm or less. This alloy has low core loss, high permeability and low magnetostriction.

Wide iron-based amorphous alloy, precursor to nanocrystalline alloy

Disclosed is a semi-amorphous, ductile brazing foil with a composition consisting essentially of NiFeCrPSiBMowith approximately 30 atomic percent &#x2264;a&#x2264;approximately 70 atomic percent; approximately 0 atomic percent &#x2264;b&#x2264;approximately 20 atomic percent; approximately 9 atomic percent &#x2264;c&#x2264;approximately 16 atomic percent; approximately 0 atomic percent &#x2264;d&#x2264;approximately 4 atomic percent; e&#x2264;approximately 2 atomic percent; f&#x2264;approximately 5 atomic percent; and the balance being Ni and other impurities; where c+d+e&#x3c;approximately 16 atomic percent.

Nickel-iron-phosphorus brazing alloys

Disclosed is a semi-amorphous, ductile brazing foil with a composition consisting essentially of NiFeCrPSiBMowith approximately 30 atomic percent&#x2264;a&#x2264;approximately 38 atomic percent; approximately 10 atomic percent&#x2264;b&#x2264;approximately 20 atomic percent; approximately 7 atomic percent&#x2264;c&#x2264;approximately 20 atomic percent; approximately 2 atomic percent&#x2264;d&#x2264;approximately 4 atomic percent; e&#x2264;approximately 2 atomic percent; f&#x2264;approximately 5 atomic percent; and the balance being Ni and other impurities; where c+d+e&#x3c;approximately 16 atomic percent.

Disclosed is the semi-amorphous, ductile brazing foil with composition consisting essentially of NiCrBPSiMoFewith approximately 24 atomic percent&#x2264;a&#x2264;approximately 31 atomic percent; b&#x2264;approximately 3 atomic percent; approximately 9 atomic percent&#x2264;c&#x2264;approximately 11 atomic percent; approximately 2 atomic percent&#x2264;d&#x2264;approximately 4 atomic percent; e&#x2264;approximately 2 atomic percent; f&#x2264;approximately 1 atomic percent; and the balance being Ni and other impurities; where b+c+d&#x3c;approximately 16 atomic percent.

Nickel-chromium-phosphorous brazing alloys

A ferromagnetic amorphous alloy ribbon includes an alloy having a composition represented by FeSiBCwhere 80.5&#x2266;a&#x2266;83 at. %, 0.5&#x2266;b&#x2266;6 at. %, 12&#x2266;c&#x2266;16.5 at. %, 0.01&#x2266;d&#x2266;1 at. % with a+b+c+d=100 and incidental impurities, the defect length along a direction of the ribbon's length being between 5 mm and 200 mm, the defect depth being less than 0.4&#xd7;t &#x3bc;m and the defect occurrence frequency being less than 0.05&#xd7;w times within 1.5 m of ribbon length, where t and w are ribbon thickness and ribbon width, respectively, and the ribbon in its annealed state and straight strip form of the ribbon, has a saturation magnetic induction exceeding 1.60 T, and exhibits a magnetic core loss of less than 0.14 W/kg when measured at 60 Hz and at 1.3 T induction level. The ribbon is suitable for use in transformer cores, rotational machines, electrical chokes, magnetic sensors and pulse power devices.

Ferromagnetic amorphous alloy ribbon and fabrication thereof

A ferromagnetic amorphous alloy ribbon, a method of fabricating a ribbon and a wound transformer core are provided. The ribbon includes an alloy of FeSiBCwhere 80.5&#x2266;a&#x2266;83 at. %, 0.5&#x2266;b&#x2266;6 at. %, 12&#x2266;c&#x2266;16.5 at. %, 0.01&#x2266;d&#x2266;1 at. % with a+b+c+d=100, and is cast from a molten state of the alloy, having a-surface tension of greater than or equal to 1.1 N/mi,. A defect length along a direction of the ribbon's length is between 5 mm and 200 mm, a defect depth less than 0.4 &#xd7;t &#x3bc;m and a defect occurrence frequency less than 0.05 &#xd7;w times within 1.5 m of ribbon length, where t is the ribbon thickness and w is the ribbon width in mm. The ribbon has a saturation magnetic induction exceeding 1.60 T and a magnetic core loss of less than 0.14 W/kg when measured at 60 Hz and at 1.3 T induction level in an annealed straight strip form, and a core magnetic loss of less than 0.3 W/kg and an exciting power of less than 0.4 VA/kg in an annealed wound transformer core form and is suitable for use in transformer cores, rotational machines, electrical chokes, magnetic sensors and pulse power devices.

Ferromagnetic amorphous alloy ribbon with reduced surface defects and application thereof

A ferromagnetic amorphous alloy ribbon includes an alloy having a composition represented by FeSiBCwhere 80.5&#x2266;a&#x2266;83 at. %, 0.5&#x2266;b&#x2266;6 at. %, 12&#x2266;c&#x2266;16.5 at. %, 0.01&#x2266;d&#x2266;1 at. % with a+b+c+d=100 and incidental impurities, the ribbon being cast from a molten state of the alloy with a molten alloy surface tension of greater than or equal to 1.1 N/m on a chill body surface; the ribbon having a ribbon length, a ribbon thickness, and a ribbon surface facing the chill body surface; the ribbon having ribbon surface protrusions being formed on the ribbon surface facing the chill body surface; the ribbon surface protrusions being measured in terms of a protrusion height and a number of protrusions; the protrusion height exceeding 3 &#x3bc;m and less than four times the ribbon thickness, and the number of protrusions being less than 10 within 1.5 m of the cast ribbon length; and the alloy ribbon in its annealed straight strip form having a saturation magnetic induction exceeding 1.60 T and exhibiting a magnetic core loss of less than 0.14 W/kg when measured at 60 Hz and at 1.3 T induction level in its annealed straight strip form. The ribbon is suitable for transformer cores, rotational machines, electrical chokes, magnetic sensors, and pulse power devices.

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Myrtle Beach, SC, United States of America

Eric Theisen