Advanced Magnetic Materials for Energy and Power Conversion Applications: Structures and Modelling of Soft Magnetic Materials
Sponsored by: TMS Functional Materials Division, TMS: Magnetic Materials Committee
Program Organizers: Richard Beddingfield, GE; Daniel Salazar, BCMaterials; Alex Leary, NASA Glenn Research Center; Huseyin Ucar, California Polytechnic University,Pomona; Yongmei Jin, Michigan Technological University; Arcady Zhukov, University of the Basque Country
Wednesday 8:30 AM
March 17, 2021
Room: RM 25
Location: TMS2021 Virtual
Session Chair: Richard Beddingfield, GE
8:30 AM Invited
Advanced Magnetics for Power and Energy Development (AMPED) : A New Consortium Model for US Power Magnetics Research and Workforce Development: Paul Ohodnicki1; Brandon Grainger1; Michael McHenry2; Maarten DeBoer2; Subhashish Bhattacharya3; Richard Beddingfield3; 1University of Pittsburgh; 2Carnegie Mellon University; 3North Carolina State University
Trends towards electrification are driving the needs for improved soft magnetic materials that can operate at unprecedented combinations of switching frequencies and power levels, as well as engineered components which are highly power dense yet extremely efficient. Successfully tackling these challenges will require an interdisciplinary skill set spanning materials science, applied physics, and electrical engineering, as well as close collaborations between end-users of components (motors, transformers, inductors, etc.) and the materials and manufacturing community. This presentation will highlight a newly established consortium to successfully realize the necessary educational and research ecosystem required to support this emerging area of importance moving into the future. Recent technical successes by existing partners will be highlighted as well as new and existing facilities available through the partner institutions. An overview of future areas of strategic importance to the consortium will be highlighted with opportunities for establishing new collaborations and partnerships moving into the future.
9:00 AM
Radio Frequency Rapid Thermal Processing of Nanocrystalline Soft Magnetic Alloys: Ahmed Talaat1; David Greve2; Paul Ohodnicki1; 1University of Pittsburgh; 2DWGreve Consulting
Controllable and fast heating profiles provide unique capabilities to realize enhanced soft magnetic properties of amorphous and nanocrystalline materials in conventional nanocrystalline alloys, as well as alloy chemistries for which carefully controlled annealing processes play a critical role in realizing desired properties tailored within a large degree of flexibility. In this work, we explore radio frequency induction heating processing of a range of different alloy systems in order to produce rapid thermal heating profiles enabling nanocrystallization. Simulation of electromagnetic heating effects and impacts on microstructures and phase transformation upon heat generation were performed. A comparison of traditional and induction annealing approaches will be presented along with the results of structural and magnetic property characterization.
9:20 AM
Soft Magnetic Fe-Co-Cu Supersaturated Solid Solutions by Severe Plastic Deformation: Martin Stuckler1; Heinz Krenn2; Lukas Weissitsch1; Stefan Wurster1; Andrea Bachmaier1; 1Erich Schmid Institute of Materials Science, Austrian Academy of Sciences; 2Institute of Physics, University of Graz
Severe plastic deformation can be used to obtain grain sizes in the nanocrystalline regime in bulk samples. With high-pressure torsion (HPT) in particular, any desired amount of strain can be applied continuously, yielding cylindrical specimens sizing up to several centimeters. Using powders as starting materials, any composition is accessible. Furthermore, also intermixing of several binary, thermodynamically non-miscible systems is possible. In the Co-Cu system in particular, single-phase supersaturated solid solutions have already been processed, whereas samples with large Co-fractions exhibit soft magnetic properties. To further improve the magnetic properties, Co is partially substituted with Fe. The focus is on the formation of supersaturated solid solutions by HPT-deformation. Microstructural properties, as revealed by electron microscopy and X-ray diffraction, are correlated to the magnetic properties, measured with DC-SQUID magnetometry and hysteresographic measurements. Furthermore, promising compositions are exposed to annealing treatments, to investigate the thermal stability and the evolution of magnetic properties.
9:40 AM
Accurate Modelling of Soft Magnetic Materials for Power Applications Using Finite Element Methods: Alex Leary1; Byron Beddingfield2; Randy Bowman1; 1Nasa Glenn Research Center; 2North Carolina State University
Inductive component designs for high power density applications have low error margins that can approach thermal limits. Successful designs require accurate modeling of the core and winding materials, including electromagnetic and thermal properties, to determine the full impedance behavior. Finite element modeling techniques that account for core material properties are reviewed, with particular emphasis on modelling of tape wound cores. Comparisons between simulated designs and experimental prototypes are shown to illustrate strengths and weaknesses of approaches.
10:00 AM
Regression Modelling of the High-frequency Inductors Used
for Power Electronic Applications
: Sanket Parashar1; Richard Beddingfield; Subhashish Bhattacharya1; 1North Carolina State University
High Frequency (>1MHz) power converters design poses challenges from coupling current and noise in the system hardware due to parasitic capacitance and inductance. Inductors are one of the prominent magnetic materials used in HF power electronics applications whose interwinding and core-winding capacitance results in significant coupling noise in the converter. The converter performance cannot be simulated and analyzed properly by traditional equivalent circuit model, which is complicated and inaccurate at HF level. Therefore, we propose to develop the model of the inductor circuit using the regression method analysis. The modeling based on regression will be purely mathematical in nature. The mathematical model will ensure the tabulation of V-I relation for the inductorin the simulation model, which results in delivering faster and accurate results than the equivalent circuit model. Our presentation will discuss the implications of materials selection on the model and performance of the inductor.