Skip to main content
SpringerLink
Log in

Powder loading rate impact on the performances of sintered MnZn ferrites fabricated by powder injection moulding

  • Original Article
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Power electronics’ power density increase mainly depends on size reduction of passive components. Development of compact solutions having two or more magnetic functions (filtering, storage, and signal transformation) on a single-magnetic core or of cores having hollowed structures for thermal integration purposes may require advanced geometries. Ferrites’ conventional fabrication technique (uniaxial compression) presents limitations for the production of cores having advanced geometrical features. Additive manufacturing or powder injection moulding (PIM) are promising techniques that allow for the shaping of magnetics having unprecedented geometrical features. These last fabrication techniques rely on the principle of mixing a powder with a binder system made of polymers to make the parts injectable or printable. The binder system may generally constitute at least 10 wt% of the total formulation’s content (much higher than for the conventional process: 2–3 wt%). The goal of this study was to analyze the impact of the binder amount (11.5, 15.3, 21.3 and 29.6 wt%, what corresponds to a MnZn ferrite powder loading rate of 88.5, 84.7, 78.7 and 70.4 wt%, respectively) inside a formulation designed for PIM. The formulations were made by extrusion, then injected in a pressing machine, debinded and finally sintered at same time (four different PIM samples per batch) in a furnace having partial oxygen pressure control. Our results showed that the power losses were not the lowest ones for the samples having the highest loading rates. The cores fabricated with a loading rate of 84.7 wt% (50 vol%) generated the lowest losses (on the whole frequencies range; between 100 and 1000 kHz/50 mT and temperatures range; between 25 and 110 °C). This behaviour was attributed to lower hysteresis losses (better magnetic phase purity). The power losses of sintered ring-shape cores achieved 88 mW/cm3 at 500 kHz/50 mT/85 °C. The losses that have been obtained for the parts fabricated by PIM were similar to the ones given by the ferrite powder supplier (conventional fabrication). These results pave the way to the fabrication of advanced cores in applications where a high level of compactness will be required as for on-board-chargers for battery electric vehicles applications.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

Data and code Availability

Not applicable

References

  1. Kasper, M.J., et al. (2022) Next generation GaN-based architectures: from 240W USB-C adapters to 11kW EV on-board chargers with ultra-high power density and wide output voltage range. in international exhibition and conference for power electronics, intelligent motion, renewable energy and energy management. Nuremberg, Germany. 2022

  2. Bohnke, M., et al. (2018) Prototyping and testing embedded transformer for 100W 1MHz GaN converter, in 20th European Conference on Power Electronics and Applications. Institute of Electrical and Electronics Engineers Inc.: Riga, Latvia

  3. Stojadinović, M. and J. Biela. (2018) Modelling and design of a medium frequency transformer for high power DC-DC converters. in 2018 International Power Electronics Conference (IPEC-Niigata 2018 -ECCE Asia)

  4. Nitzsche, M., et al. (2020) Design flow of a compact high-frequency DC/DC converter with optimum average efficiency in a wide operation range. in 2020 22nd European Conference on Power Electronics and Applications (EPE'20 ECCE Europe)

  5. Delette G, Soupremanien U, Loudot S (2022) Thermal management design of transformers for dual active bridge power converters. IEEE Trans Power Electron 37(7):8301–8309

    Article  Google Scholar 

  6. Hosseini, R. and R. Cuzner. (2019) A High Frequency power transformer for isolated bidirectional DC-DC converter used for MVDC collection system in wind farmser. in 2019 8th International Conference on Renewable Energy Research and Applications (ICRERA)

  7. Knabben, G.C., et al. (2018) New PCB Winding ”Snake-Core” Matrix Transformer for Ultra-Compact Wide DC Input Voltage Range Hybrid B+DCM Resonant Server Power Supply. in 2018 IEEE International Power Electronics and Application Conference and Exposition (PEAC)

  8. Ahmed, M.H., et al. (2019) High-efficiency, high-density isolated/regulated 48V bus converter with a novel planar magnetic structure. in 2019 IEEE Applied Power Electronics Conference and Exposition (APEC)

  9. Hoang, K.D. and J. Wang. (2012) Design optimization of high frequency transformer for dual active bridge DC-DC converter. in 2012 XXth International Conference on Electrical Machines

  10. Mu, M., et al. (2015) Design of integrated transformer and inductor for high frequency dual active bridge GaN charger for PHEV. in 2015 IEEE Applied Power Electronics Conference and Exposition (APEC)

  11. Cougo, B. and J.W. Kolar. (2012) Integration of leakage inductance in tape wound core transformers for dual active bridge converters. in 2012 7th International Conference on Integrated Power Electronics Systems (CIPS)

  12. VAC - Advanced magnetic solutions | VAC. Available from: https://vacuumschmelze.com/Newsroom/combichoke-cmc-and-dmc-combined-n2484. Accessed 15 Dec 2022

  13. Johnson M et al (2018) IEEE ITRW working group position paper-packaging and integration: unlocking the full potential of wide-bandgap devices. IEEE Power Electron Mag 5(2):26–33

    Article  Google Scholar 

  14. Peng E et al (2017) Ferrite-based soft and hard magnetic structures by extrusion free-forming. RSC Adv 7(43):27128–27138

    Article  Google Scholar 

  15. Liu L et al (2018) Ferrite paste cured with ultraviolet light for additive manufacturing of magnetic components for power electronics. IEEE Magn Lett 9:5102705

    Article  Google Scholar 

  16. Hu Y et al (2022) Preparation of Mn–Zn ferrite ceramic using stereolithography 3D printing technology. Ceram Int 48(5):6923–6932

    Article  MathSciNet  Google Scholar 

  17. Soupremanien U et al (2020) Soft ferrite material by powder injection molding process for power electronics. IEEE Trans Magn 56(12):1–7

    Article  Google Scholar 

  18. Rolere S et al (2021) New insights on the porous network created during solvent debinding of powder injection-molded (PIM) parts, and its influence on the thermal debinding efficiency. J Mater Process Technol 295:117163

    Article  Google Scholar 

  19. Servant F, Tiquet P (2011) Melange maitre pour le moulage par injection de poudre ceramique ou metallique et methode pour sa preparation, C. Cabinet Laurent et Charras: Fr, Grenoble, Editor

    Google Scholar 

  20. Shewmon P (1963) Diffusion in Solids. Springer

    Google Scholar 

  21. Zaky MT, Soliman FS, Farag AS (2009) Influence of paraffin wax characteristics on the formulation of wax-based binders and their debinding from green molded parts using two comparative techniques. J Mater Process Technol 209(18):5981–5989

    Article  Google Scholar 

  22. Suh JJ, Song BM, Han YH (2000) Temperature dependence of power loss of Mn-Zn ferrites at high frequency. IEEE Trans Magn 36(5):3402–3404

    Article  Google Scholar 

  23. Bertotti G (2008) Connection between microstructure and magnetic properties of soft magnetic materials. J Magn Magn Mater 320(20):2436–2442

    Article  Google Scholar 

Download references

Acknowledgements

The authors would like to thank Gerard Delette for the fruitful discussions related to this current analysis.

Author information

Authors and Affiliations

  1. Grenoble Alpes University, CEA-LITEN, 17 Avenue des Martyrs, 38054, Grenoble Cedex 9, France

    Ulrich Soupremanien, Hugo Dayde & Myriam Dalmasso

Authors
  1. Ulrich Soupremanien
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hugo Dayde
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Myriam Dalmasso
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

US: conceptualization, data curation, formal analysis, investigation, methodology, validation, and writing. HD: investigation and validation. MD: investigation and validation

Corresponding author

Correspondence to Ulrich Soupremanien.

Ethics declarations

Ethical approval

Not applicable

Competing interests

The authors declare no competing interests.

Additional information

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Soupremanien, U., Dayde, H. & Dalmasso, M. Powder loading rate impact on the performances of sintered MnZn ferrites fabricated by powder injection moulding. Int J Adv Manuf Technol 129, 3917–3931 (2023). https://doi.org/10.1007/s00170-023-12520-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-12520-9

Keywords

Search

Navigation