Advanced Magnetic Materials for Energy and Power Conversion Applications: Application of Advanced Soft Magnetic Materials in Power Electronics and Motors
Sponsored by: TMS Functional Materials Division, TMS: Magnetic Materials Committee
Program Organizers: Daniel Salazar, BCMaterials; Alex Leary, NASA Glenn Research Center; Markus Chmielus, University of Pittsburgh; Ryan Ott, Ames Laboratory; Arcady Zhukov, University of the Basque Country
Monday 8:00 AM
February 24, 2020
Room: Del Mar
Location: Marriott Marquis Hotel
Session Chair: Alex Leary, NASA Glenn Research Center
8:00 AM Invited
Metal Amorphous Nanocomposite (MANC) Soft Magnetic Materials (SMM) for Motor Applications.: Michael McHenry1; Satoru Simizu1; Kevin Byerly2; Paul Ohodnicki2; Subhashish Bhattacharya3; 1Carnegie Mellon University; 2NETL; 3North Carolina State University
Metal amorphous nanocomposites (MANC)s are promising soft magnetic materials (SMM)s offering low power loss at high frequency and high flux density for high power densities. I will review their potential for applications in rotating electrical machinery. FeNi-based MANCs exhibit high permeability making them attractive for rotating machinery. High speed motor (HSM) applications exploiting MANCs in efficient axial motor topologies proposed. Widespread applications require scaled MANC manufacturing and proliferation of new HSM designs. I will summarize recent efforts to (a) increase resistivity and characterize passivating oxides in Fe-Ni-based MANC SMMs; (b) prototype motor topologies that do not require rare earth permanent magnets or can operate with RE-lean permanent magnets (c) scaling and post-processing of MANC cores for rotor and stator application and (d) development of new MANC compositions which are attractive for conventional stamped motor laminates. The potential for HSMs will be discussed in light of materials scarcity issues.
8:25 AM Invited
Strain Annealed Co-rich and Fe-rich Nanocrystalline Materials for Inductive Components: Christian Polak1; 1Vacuumschmelze Gmbh & Co. Kg
Among metallic soft magnetic materials, amorphous and nanocrystalline alloys are the most promising candidates for advanced and energy-efficient inductive components. Nowadays there is the need for less environmental loads, respectively lower electrical losses and/or for miniaturization of inductive components caused by higher operating frequency of SiC-based switches. Nanocomposite Co-rich or Fe-rich soft magnetic materials are particularly suitable for these applications with low core losses at higher frequencies and high saturation induction to archive high power density. The addressed alloys are typically cast into thin amorphous ribbons by planar flow casting processes. A short time annealing of the ribbons under tensile stress along the ribbon axis leads then to huge anisotropy, respectively to small and extremely small permeability and perfect linear hysteresis loops. Recent results of various strain annealed Co-rich or Fe-rich alloy compositions will be presented and opportunities for future application will be highlighted.
8:55 AM Invited
New Trends in the Amorphous and Nanocrystalline Soft Magnetic Ribbon Market: Eric Theisen1; 1Metglas Inc.
Here we update the status of the various soft magnetic alloys currently produced by Metglas and highlight their primary industrial applications. The distribution transformer market continues to be the largest segment of Fe-based amorphous ribbon and has been shifting towards thicker ribbon with higher induction levels (1.63T) and with increased stacking factor (>90%). Emerging trends with electric motors also utilize these advancements in amorphous ribbon properties. There are many approaches to incorporate amorphous ribbon into the motor components and we will discuss the methods that have been industrially adopted. FeCo based amorphous alloys further enhance the induction levels (1.8T) and can be viable in these applications. There are also new FeCo and FeNi nanocrystalline alloys being developed specifically suited towards motor applications that will be discussed.
9:20 AM Invited
Processing and Advanced Characterization of Selectively Paramagnetized Laminates for Synchronous Reluctance Motors: Orlando Rios1; Hunter Henderson1; Min Zou2; Craig Bridges1; Michael Kesler1; Michael Brady1; 1Oak Ridge National Laboratory; 2GE Global Research
A primary limiting factor in the efficiency and flexibility of electric motors and generators is the ability of rotors to withstand mechanical stresses at high rotational velocity. One way to strengthen rotors is to form them from a monolithic material rather than an assembly, but this leads to uncontrolled flux paths and flux leakage associate with support structures. To tune flux paths and maintain a monolithic material, we selectively transform ferrite to austenite through masking and a high temperature nitrogenation treatment in a high-Cr soft magnetic steel. In this study, the kinetics of transformation are explored through magnetization, microstructure, and high-speed differential scanning calorimetry. Additionally, neutron diffraction methods are used to evaluate residual stress that could affect performance in the materials.
9:50 AM Break
10:05 AM Invited
Multi-objective Design of Permeability Engineered Soft Magnetic Metal Amorphous Nanocomposite Cores: Paul Ohodnicki1; Vinicius Cabral Do Nascimento2; Richard Beddingfield2; Kevin Byerly2; Seung-Ryul Moon2; Scott Sudhoff3; 1National Energy Technology Laboratory (presently at University of Pittsburgh); 2National Energy Technology Laboratory; 3Purdue University
Benefits of spatial permeability optimization in the magnetic core for electromagnetic devices with emphasis on DC and AC inductors will be explored in detail, using the achievable properties obtained through strain annealing treatment of Metal Amorphous Nanocomposite (MANC) alloys. This capacity introduces a new design element which involves the spatial variation of permeability throughout an inductor core that can result in superior performance. However, the device characteristics result from a multitude of aspects besides the material properties, including its geometry and operational context (e.g. frequency, current waveform, and temperature constraints). In order to fully leverage the capacity of spatial dependent permeability engineering, the geometry, windings, and core permeability should be optimized simultaneously. Comparisons will be presented for viable solutions using permeability tuned un-gapped inductors against traditional gapped devices through multi-objective design optimization. Case studies included in this work evaluates AC and DC inductors with toroidal and racetrack parametrized geometries.
10:25 AM
Dual Phase Soft Magnetic Laminates for Permanent Magnet Assisted Synchronous Reluctance Electric Machines: Shenyan Huang1; Min Zou2; Wanming Zhang1; Joseph Zierer1; Anoop Jassal1; Vandana Rallabandi1; Steve Buresh1; PR Subramanian1; 1GE Research; 2GE Global Research
Dual phase soft magnetic laminates benefit electric machine performance by reducing flux leakage in critical locations in the laminates. Driven by the market needs for high power density and high-speed electric machines, the performance of a synchronous reluctance (SynRel) machine using dual phase soft magnetic laminates together with different types of permanent magnets (PMs) was assessed. Finite element analysis of mechanical stress distribution in the dual phase laminate rotor was carried out to evaluate material’s mechanical strength requirement for the PM-assisted SynRel machines. The results suggest that dual phase soft magnetic materials with high mechanical strength, high saturation magnetization, high permeability, and low loss are highly desired for further improvement in machine performance. This talk will also present the current status and recent development within GE, including new alloy development, processing-properties-performance relationships, and additional applications.
10:45 AM
Continuous Strain Anneal Processing of Amorphous Ribbons for Inductor Applications: Kevin Byerly1; Paul Ohodnicki1; Seungryul Moon1; Byron Beddingfield2; Satoru Simizu3; Alex Leary4; Vladimir Keylin4; Eric Theisen5; M.E. McHenry3; 1National Energy Technology Laboratory; 2North Carolina State University; 3Carnegie Mellon University; 4NASA Glenn Research Center; 5Metglas, Inc.
Co-based metal amorphous nanocomposites (MANCs) can be used for various inductor and sensor applications. The as-quenched Co-based amorphous metal ribbons are suitable materials for continuous strain annealing due to their extraordinary mechanical and magnetic properties. During the process of strain annealing, a transverse magnetic anisotropy is induced and is proportional to the applied tension during annealing giving rise to a controllable value of relative permeability. It is this control of magnetic properties which enables the control of temperature rises within the component. We present several tuned permeability profiles for large-scale production of inductor cores for a specified geometry. In addition, analytical models are compared to the experimental hardware examples for further study of localized core losses. By quantifying the magnetic property variations due to strain annealing, we will allow for the incorporation of loss model predictions and integration of optimal strain annealing profiles to achieve final core temperature profiles.
11:05 AM
Designing High Efficiency, High Power Transformers with Metal Amorphous Nanocomposites: Richard Beddingfield1; Subhashish Bhattacharya2; Kevin Byerly3; Seung Moon3; Alex Leary4; Ronald Noebe4; Randy Bowman4; Michael McHenry5; Paul Ohodnicki1; 1National Energy Technology Laboratories; 2North Carolina State University; 3Leidos, Contractor for National Energy Technology Laboratory; 4NASA Glenn Research Center; 5Carnegie Mellon University
Metal amorphous nanocomposite (MANC) materials are attractive solutions for high power medium frequency transformers needed in advanced wide bandgap-based power converters. Advances in material design and processing enabling access to new alloy compositions, tailored ribbon width, and engineered permeabilities through strain and magnetic field annealing have provided more options and capabilities for magnetic component design based these emerging materials. This presentation will discuss lessons learned from the use of MANC materials in the design of a 10 kW, 20 kHz transformer for a dual active bridge. We will present key performance metrics of four transformer designs that include advanced research cores as well as commercially available cores. We will also present identifying characteristics from post processing that can have significant performance implications. This work will provide tools for core manufactures and magnetics engineers to further improve designs to achieve high performance components to meet the requirements of advanced power converters.
11:25 AM
Tunable Power Inductors Utilizing Magnetoelectric PZT/Metglas Composites: Mark Nations1; Paul Ohodnicki1; Subhashish Bhattacharya1; 1North Carolina State University
Voltage tunable inductors utilizing multiferroic composite cores are investigated. Cores comprised of a piezoelectric phase (PZT) and magnetostrictive phase (Metglas ribbon) demonstrate tunable magnetic permeability by magnetoelastic coupling between phases. Inductors created from such composite cores show large inductance tunability, quality factor tunability, and low energy consumption. The relationship between magnetocrystalline anisotropy and stress-induced anisotropy in the PZT/Metglas system is investigated. While previous work focused on small-scale devices, a tunable inductor with these qualities is highly desirable for power conversion and control. Two topologies for magnetoelectric power inductors are investigated. Their feasibility is evaluated in a case study of a DC circuit breaker where a tunable inductor is used to limit fault current. Results are compared to existing approaches to tunable power inductors such as saturable reactors.