|About this Abstract
||2024 TMS Annual Meeting & Exhibition
||Advanced Soft Magnets and Magnetocaloric Materials: An FMD Symposium in Honor of Victorino Franco
||Metal Amorphous Nanocomposite (MANC) Materials for High High Speed Axial Motors
||Michael E. McHenry, K. Schneider, Satoru Simizu, James Egbu, M. P. DeBoer, Eric Theisen
|On-Site Speaker (Planned)
||Michael E. McHenry
Metal amorphous nanocomposites (MANC) are soft magnetic materials (SMMs) studied for magnetic tape wound core (TWC) components in high-speed motor (HSM) applications. MANCs consist of soft magnetic nanocrystals embedded in a continuous, resistive amorphous matrix, providing low eddy current losses. TWC performance arising from low core loss enables magnetic switching at 1- 100 kHz; (Fe70Ni30)85Nb0.5B14.5Si0 (Bs = 1.5 T) and (Fe70Ni30)80Nb4B14Si2 MANCs (W1T,400Hz = 0.5 W/Kg, Hc = 2.4 A/m, ýr > 35000). Co additions increase inductions and Curie temperatures and reduce magnetostriction to ~1 ppm. Axial HSMs require TWCs to have robust mechanical properties sufficient for: (1) core winding and strain annealing; (2) manufacturing rotor laminates and slots (3) stress tolerance at high rotational speeds. We summarize manufacturing issues for MANC rotors and stators using RE-lean materials as studied in USDOE AMO and VTO projects. Efforts include (1) production steps for TWCs; (2) MANC ribbon mechanical properties (strength, Weibull and Young’s Moduli); (3) epoxy wetting of MANCs for vacuum impregnation bonding; (4) vacuum impregnation epoxy bonding for rotor mechanical integrity, (5) failure mechanisms and figure of safety issues in MANC/epoxy laminates. These target paths to efficient HSMs for powers of ~34 kW for EV applications. Considerations of alloy component criticality will be reviewed. A future path for high temperature motors and active cooling will also be presented in light of these motor topologies.