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Thermal profile shaping and loss impacts of strain annealing on magnetic ribbon cores

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Abstract

The use of the advanced manufacturing technique of strain annealing for nanocomposite magnetic ribbons enables control of relative permeabilities and spatially dependent permeability profiles. Tuned permeability profiles enable enhanced control of the magnetic flux throughout magnetic cores, including the concentration or dispersion of the magnetic flux over specific regions. Due to the correlation between local core losses and temperature rises with the local magnetic flux, these profiles can be tuned at the component level for improved losses and reduced steady-state temperatures. We present analytical models for a number of assumed permeability profiles. This work shows significant reductions in the peak temperature rise with overall core losses impacted to a lesser extent. Controlled strain annealing profiles can also adjust the location of hotspots within a component for optimal cooling schemes. As a result, magnetic designs can have improved performance for a range of potential operating conditions.

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Abbreviations

a:

Area of a material for thermal impedance

α:

Frequency-dependent loss exponent

B:

Magnetic flux density

B avg :

Average flux density over toroid profile

β:

Magnetic flux density loss exponent

Bz[a, b]:

Incomplete Beta function

c:

Exponent in exponential permeability profile

C:

Circumference of a circular path

C c :

Thermal capacitance of toroid core

f:

Frequency of excitation waveform

F:

Core fill factor, ratio of total material thickness to core thickness

g:

Ratio between slope and offset magnetic permeability terms

h:

Height of magnetic ribbon in the z direction

I:

Current flowing through excitation coil

K:

Power loss scalar term

k t :

Thermal conductivity

k c :

Thermal conductivity of the magnetic ribbon

k G :

Thermal conductivity of the gap between magnetic ribbon layers

λ:

Ratio between outer and inner radius of toroid

L:

Magnetic inductance of wound toroid

l:

Length of a material for thermal impedance

λ:

Ratio between outer radius and inner radius of a toroid core

L r :

Length of ribbon

l r :

Length of ribbon to apply strain for a given radius

l G :

Length of region between ribbon layers

l Gz :

Length of region between ribbon material and external free space

L n :

Layer number # of a wound toroid

μ:

Magnetic permeability of core material

μ0:

Magnetic permeability of free space

μ1:

Magnetic permeability following the graded with offset profile

μc:

Magnetic permeability following the constant profile

μe:

Magnetic permeability following the exponential profile

μs:

Slope term for the graded and offset graded profiles

N:

Number of turns of excitation coil

N L :

Total number of layers of ribbon for the full toroid core

n:

Ribbon layer number between 1 and NL

\(\hat P\) :

Permeance of magnetic core

ϕ:

Magnetic flux

P:

Power loss due to magnetic core excitation

P loc :

Power loss in the local region of the core

Q:

Heat injection into the core

r:

Radius of layer of inspection for toroid core

r i :

Inner radius of toroid core

R:

Thermal impedance

R t :

Tangential thermal impedance

R r :

Radial thermal impedance

t:

Magnetic ribbon thickness

T:

Temperature of magnetic core

T amb :

Ambient temperature

V:

Volume of magnetic material

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ACKNOWLEDGMENTS

The authors would like to thank the Oak Ridge Institute for Science Education (ORISE) for funding and financial support. Similarly, the authors would like to thank the Department of Energy for support to the diverse team through DOE EERE initiative SuNLaMP program and the National Energy Technology Lab ongoing research under the RES contract DE-FE0004000. The authors also acknowledge funding support through the National Energy Technology Laboratory’s research support of the DOE OE Transformer Reliability and Advanced Components (TRAC) Program.

Author information

Authors and Affiliations

  1. North Carolina State University, Raleigh, North Carolina, USA

    Richard Beddingfield & Subhashish Bhattacharya

  2. National Energy Technology Laboratory, Pittsburgh, Pennsylvania, USA

    Kevin Byerly

  3. Contractor to the US Department of Energy, AECOM, Pittsburgh, Pennsylvania, USA

    Kevin Byerly

  4. Material Science and Engineering, Carnegie Mellon University, Pittsburgh, Pennsylvania, USA

    Satoru Simizu & Mike McHenry

  5. Materials and Structures Division, NASA Glenn Research Center, Cleveland, Ohio, USA

    Alex Leary

  6. National Energy Technology Laboratory and Materials Science and Engineering, Carnegie Melon University, Pittsburgh, Pennsylvania, USA

    Paul Ohodnicki

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  1. Richard Beddingfield
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Correspondence to Richard Beddingfield.

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This author was an editor of this journal during the review and decision stage. For the JMR policy on review and publication of manuscripts authored by editors, please refer to http://www.mrs.org/editor-manuscripts/.

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Beddingfield, R., Bhattacharya, S., Byerly, K. et al. Thermal profile shaping and loss impacts of strain annealing on magnetic ribbon cores. Journal of Materials Research 33, 2189–2206 (2018). https://doi.org/10.1557/jmr.2018.157

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