Overview of Soft Magnetic Materials
by Mr. Andy Hayling of MagDev Ltd

A critical aspect of any design is the choice of material. Knowing the pros and cons of available materials eliminate early design hiccups thus allowing the designer to focus only on workable solutions. A comparison of material properties can prove a useful guide for applications using soft magnetic components

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Effect of passive inverter output motor filters on drive systems
by Dr. Dennis Kampen of BLOCK Transformatoren-Elektronik GmbH

The evaluation shows the effect of different on the market available inverter output filters on important drive system characteristics. Each filter is explained and the filter effect on motor insulation, inverter losses, cable losses, motor losses, audible noise, EMI, bearing currents and costs is compared. This paper offers a comprehensive overview and might help drive system designers in choosing the most suitable passive filter solution.

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Advanced Production of Lamination Stacks from High-Saturation Cobalt-Iron Materials
by Dr. Niklas Volbers of VACUUMSCHMELZE GmbH & Co KG

There is an increasing demand for electrical machines with very high power density, especially in the emerging field of electrical flight. If a high power-to-weight ratio is required, cobalt-iron alloys (CoFe) are the best choice among all commercial soft magnetic materials. They offer the highest saturation induction of up to 2.4 T, enabling highest power densities or smallest machine volume and/or weight. CoFe materials are typically being used in strip thickness of 0.20 mm or even down to 0.05 mm, which is much thinner than the standard gauges used for electrical steels. To preserve the superior magnetic properties (regarding both induction and core loss) it is necessary to develop a consistent production route that takes into account the specific material properties. This includes the forming, handling, annealing and stacking of the laminations. The presentation will give an overview of the available high saturation material grades and their properties, including the new high-induction material VACOFLUX® X1 with a reduced Co content of 17%. In addition, different part production routes with their respective advantages and challenges will be discussed. While the prototype production routes offer flexibility in design and short lead times, the serial production routes aim at lower production cost and better scalability. ® registered trademark of VACUUMSCHELZE GmbH & Co. KG

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New Magnetic Powder Core & Applications
by Mr. Andy Hayling on behalf of KDM

As a specialist supplier of iron powder cores KDM has the widest range of alloy powder materials available. Latest developments and improved performances over 1st generation materials are highlighted, providing comparison data and information on available shapes, and targeted applications.

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Degradation of Soft Magnetic Materials
by Dr. Philip Anderson of Cardiff University

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Introduction to MAGMA
by Mr. Kevin Jones & Dr. Chris Harrison of Cardiff University

This presentation will be an introduction to the Magnetic Materials and Applications (MAGMA) operation that launched in the Cardiff University School of Engineering in 2019. We are part-funded by the European Regional Development Fund (ERDF) via Welsh Government (£1.05m in total), Cardiff University and industrial partners. The operation plans to establish a compelling combination and breadth of academic expertise alongside commitments from major industry partners, that builds towards a centre of excellence within Europe for magnetic materials within five to seven years. This presentation will offer an introduction to our group, detail how the funding will be used, what our short medium- and long-term aims are and then detail the facilities that we have available.

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SMC - More than Materials
by Mr. Lars Hultman of Höganäs AB

SMC materials and its processing to components, main features of the material / concept and the resulting benefits in different applications, focusing on Automotive.

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Validation of metal alloy powder core under pulse condition
by Mr. JC Sun of Bs&T Frankfurt am Main GmbH

Metal alloyed composite with its gradual soft saturation experiences exponential growth in the last decades, validation of such kind of soft magnetic composite is a challenge. Damped oscillation is good alternative to characterize the magnetic properties, in saturation and loss i.e. quality factor.

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New high frequency metal magnetic materials developments and future trends
by Dr. Junwu Nie of DMEGC

The third-generation semiconductor substrate materials, such as SiC, are characterized by wide band gap, high thermal conductivity, high saturation electron drift rate and high bonding energy, which meet the requirements of modern electrons for high temperature, high power, high voltage, high frequency and radiation resistance. Chip development drive electronic device materials to follow up with high frequency. Usually in weak current control environment: the requirements of UPS and the purity of electric energy used in precision instruments make filtering necessary. The power factor correction function must be equipped in the circuit with inductor in the load to reduce the phase difference loss. Depending on the protection of multiple induction devices, soft magnetic materials are widely used. The superfine insulating powders of FeSiAl and FeNi are applied to the development of integrated molded inductors, or special-shaped "H" and " П " small inductors, respectively. As well as, the n！stairs need to climb before great breakthrough of technology from powders to devices for current control.

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Transformer design for Full-Bridge Phase Shift converter
by Dr. José María Molina, Mr. Lucas Nicieza of Frenetic

High frequency magnetics have become the main bottleneck in the power supply design, in order to increase the power density. The topology Full-Bridge Phase Shift is a wide commonly used in power supplies where galvanic isolation is required for power levels above 200 W. In this presentation, we will discuss some key aspects of the design of this transformer.

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Steel selection for eddy current brakes in magnetically levitated vehicles
by Dr. Sigrid Jacobs of ArcelorMittal

Within the move towards green transport systems, ArcelorMittal has investigated further the electromagnetic materials needed for linear electrical machines, as systems to provide propulsion, braking and levitation, in magnetically levitated trains or hyperloop. This paper more specifically tackles the braking functionality, which can be provided by regenerative braking of propulsion systems or with dedicated braking linear motors. Eddy-current brakes have previously been implemented in high-speed rail applications as a method to avoid mechanical friction systems, which have the disadvantage of creating noise and wear on the contact zones.These brakes typically consist of a number of electromagnets that are attached to the bogie, positioned above the ferromagnetic rail, which acts as the stator. The application of a DC excitation to the electromagnet results in the induction of magnetic flux in the stator and, hence, eddy currents due to the relative movement between bogie and stator. Magnetically levitated trains and Hyperloop have unique challenges related to the design of eddy-current brakes, due to the high-speed operation and weight restrictions. Further, these brakes also generate a variable force that is normal to the airgap, which may interfere with the operation of the levitation functionality on these vehicles. These considerations call for the use of specific magnetic materials with suitable combinations of permeability, saturation and resistivity. This paper will investigate the use of a number of stator materials by using 2D transient Finite Element software. At first, stators with homogeneous material properties are analysed, comparing a number of commercially available steels. The electrical resistivity of these materials was measured according to the 4-point resistance measurement method [IEC 60404-13], whilst the magnetic permeability was measured up to 80kA/m according to the permeameter method [IEC 60404-4], implying a correct approach to saturation, as input for the modelling. Further, the effect of gradient materials is investigated in order to demonstrate the effect of specific surface properties or the use of multi-layered materials. It is shown that such materials can affect the distributions of current and flux in the stator and increase the skin depth. Finally, a thermal model is presented to demonstrate that the temperature rise of the stator remains within acceptable limits. ArcelorMittal has committed to being carbon neutral by 2050 and is already bringing forward greener steel solutions. We can therefore assure our ferromagnetic materials will be a sustainable part of the further electrified transport systems.

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