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: 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

Tuesday 2:00 PM
March 16, 2021
Room: RM 25
Location: TMS2021 Virtual

Session Chair: Alex Leary, NASA Glenn Research Center


2:00 PM  
Advances in Amorphous Core Technology for Loss Reduction in Distribution Transformers: Eric Theisen1; 1Metglas Inc.
    The US DOE minimum efficiency levels for distribution transformers have evolved over the past decades and currently the most recent 2016 standard is being considered for revisions. This talk focuses on some key points of review in the standard. The distribution transformer market continues to be the largest market for Fe-based amorphous ribbon and has been shifting towards higher induction levels (1.63T) with increased stacking factor (>90%). New grades of amorphous transformer cores with lower losses and improved designs are currently being introduced. Amorphous based transformers have always had an advantage when using a total ownership cost evaluation. However, the improvements in today’s amorphous ribbon and the increase in efficiency standards make amorphous transformers favorable in many first cost designs as well.

2:20 PM  
Magnetic Augmented Rotation System (MARS) – An Update: Nuggehalli Ravindra1; Chimaobi Ibeh1; Tyler Brunstein-Ellenbogen1; Bilal Adra1; Balraj Mani1; Tiensee Chow2; 1New Jersey Institute of Technology; 2ETD Inc.
    In recent years, there has been significant development in materials, material systems and materials processing for applications in contactless gears. In minimizing material wear and tear due to minimal or zero friction, gearless systems require no lubrication, offer extended shelf-life and exhibit minimal noise. An overview of materials that can be utilized in gearless systems is presented. Various examples and case studies of the use of contactless gears in mechanical and industrial systems as well as in devices for energy conversion are described. Growth opportunities of this evolving technology are summarized.

2:40 PM  
Overview of Magnetic Component Design for Power Converters: Richard Beddingfield1; Paul Ohodnicki2; 1North Carolina State University; 2University of Pittsburgh
    Power electronics converters rely significantly on transformers to achieve a variety of functions such as power flow control and voltage level conversion. Often, the transformer is also used to meet regulatory requirements such as galvanic isolation between the grid and distributed energy resources. Modern power converters have advanced significantly with new wide band-gap power semiconductors. In order to leverage the full capabilities of this advancement, the magnetic components must meet significant performance metrics. This presentation will provide details and guidelines for leveraging the latest in magnetic material research for component design for power converters. We will demonstrate how a materials driven design approach leads to a more optimized magnetic component which can ultimately drive the overall converter performance and remove the magnetic component bottleneck that exists in current design practices. This work will highlight the steps that are presented in a forthcoming book chapter by the authors.

3:00 PM  Invited
Permanent Magnet Biased Inductors for Power Systems Applications: Mark Nations1; 1North Carolina State University
    Inductors are a very common component in many power electronic systems. In these systems inductors typically take up a large portion of the total volume, mass, and losses. If an inductor is utilized with unidirectional current flow, then volume and mass may be substantially reduced by biasing the magnetic flux within the inductor core using permanent magnets. Such inductors can effectively double the core utilization of a traditional inductor. Permanent magnet biased inductors are therefore much smaller and lighter than equivalent unbiased inductors. Related applications include filters, unidirectional non-isolated power converters, and inrush current limiting devices.

3:30 PM  
The Effects of Stack Manufacturing Processes on the Magnetic Properties of Iron-Cobalt Alloys: Natan Aronhime1; 1Carpenter Technology
     Iron-Cobalt alloys are well known for their excellent magnetic properties and extremely high induction levels. These properties make them an attractive option when designing and manufacturing power-density electric machines. This is especially true due to the burgeoning use of high-performance electric machines in the automotive, naval, and aerospace sectors. It is well known that there is a degradation in the materials’ magnetic performance when comparing manufactured electric machine to a simple ring core or Epstein frame strip. Specifically, this phenomenon may be exacerbated in iron-cobalt alloys due to their high magnetostriction as compared with silicon-steels. Hence, stresses have a larger impact on magnetic performance of iron-cobalt alloy due to the high magnetostriction. This work examines key manufacturing processes and their impact on the overall magnetic performance of iron-cobalt alloys and assemblies.