Novel FePBNbCr glassy alloys SENNTIX with good soft-magnetic properties for high efficiency commercial inductor cores

According to a recent study, Fe-based glassy alloys are expected good soft-magnetic properties such as high saturation magnetization and lower coercive force. We focused on Fe-based glassy alloys and have succeeded in developing novel glassy Fe97-x-yPxByNb2Cr1 (x = 5-13, y = 7-15) alloys for an inductor material. The glassy alloy series of Fe97-x-yPxByNb2Cr1 (x = 5-13, y = 7-15) have high glass-forming ability with the large critical thickness of 110-150 mu m and high B-s of 1.25-1.35 T. The glassy alloy powder with chemical composition Fe77P10.5B9.5Nb2Cr1 exhibits an excellent spherical particle shape related to the lower melting point and liquid phase point. In addition, Fe-P-B-Nb-Cr powder/resin composite core has much lower core loss of 653-881kW/m(3), which is approximately 1/3 lower than the conventional amorphous Fe-Si-B-Cr powder/resin composite core and 1/4 lower than the conventional crystalline Fe-Si-Cr powder/resin composite core due to the lower coercive force of 2.5-3.1 A/m. Based on above results, the glassy Fe97-x-yPxByNb2Cr1 alloy powder enable to achieve ultra-high efficient and high quality products in a commercial inductor. In fact, the surface mounted inductor using Fe-P-B-Nb-Cr powder/resin exhibits the high efficiency of approximately 2.0% compared with the conventional inductors made of the crystalline Fe-Si-Cr powder/resin composite core. (C) 2011 Elsevier B. V. All rights reserved.