CA1140036A - Bonded amorphous metal electromagnetic components - Google Patents

Bonded amorphous metal electromagnetic components

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Publication number
CA1140036A
CA1140036A CA000340405A CA340405A CA1140036A CA 1140036 A CA1140036 A CA 1140036A CA 000340405 A CA000340405 A CA 000340405A CA 340405 A CA340405 A CA 340405A CA 1140036 A CA1140036 A CA 1140036A
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Canada
Prior art keywords
ribbons
polymer
coated
magnetic
percent
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000340405A
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French (fr)
Inventor
John H. Lupinski
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Electric Co
Original Assignee
General Electric Co
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Filing date
Publication date
Application filed by General Electric Co filed Critical General Electric Co
Priority to CA000340405A priority Critical patent/CA1140036A/en
Application granted granted Critical
Publication of CA1140036A publication Critical patent/CA1140036A/en
Expired legal-status Critical Current

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  • Soft Magnetic Materials (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)

Abstract

ABSTRACT OF THE DISCLOSURE
Magnetic cores suitable for use in transformers, generators and motors are provided. The core is formed of a laminate of layers of substantially amorphous metal laminated compressed to a rigid composite.

Description

~ G ~ oz~g This in~ention relates to the manufacture of electromagnetic components from amorphous metal ribbons by compressing and bonding said ribbons.
~ lectrical steel forms the magnetic core of almost all transformers, generators and motors. The machines in which they are employed are usually large and heavy, so that the cost per pound of magnetic material is important.
Accordingly, their cores are made of electrical steel because it is the cheapest magnetic material, albeit far from the most effective. For example, the resistivity for grain-oriented silicon steel of 12-15 mil gauge is 5G, and 15 for low carbon steel as opposed to 150u cm for amorphous magnetic alloys.
Cores are subjected to alternating and/or rotating magnetic fields and because the machine in which they are employed handle large amounts of electric power, the minimization of the energy loss per cycle i5 quite impoxtant.
The losses are primarily due to eddy currents. Eddy currents are objectionable, not onl~ because they decrease the flux, but also because they produce, heat. These currents which oppose the Inain field can be decreased by forming the core of thin sheets rather than from a solid piece. If the sheets are electrically insulated from one another, the eddy currents are forced to circulate within each lamination. Not only is the path length in each lamination now shorter but the cross-sectional area of the path is also reduced. The induced emf is therefore reduced and the net effect is a decrease in the current and in the eddy~current power loss.
For these reasons, lamina-ted construction is standard for all cores of transformers, motors or generators made from metalllc conducting materials.

In order to minimize the cost of construction, the ~i' ~(3(33Ç;
- ~D-10~9 laminations are usually thicker than would be de~ d to minimize eddy current loss. For example, the most popular lamination thickness is about 0.012 lnch, whereas for many applications laminations of 1-2 mils would be desirable. Due to the cost of forming thin sheets of electric steel and the concomitant difficulty and the cost of forming the resultant core, it would be aesirable if cores could be made from new materials which have fabrication cos-ts of thic~ laminations but the magnetic and electrical properties of thin laminations.
It is the provision of such magnetic components to which this invention is directed.
Amorphous magnetic metals, unlike normal crystalline magnetic metals, have no long range atomic order in their structure. There~ore, the directionality of properties such as magnetization normally associated with crystal anisotropy is absent. Also, unli]ce normal metals, amorphous metals are extremely homogeneous, being devoid of inclusions and structural defects. These two characteristic~ -magnetic isotropy and structural homogeneity - cJiVe a~orphous metals unusually yoo~ d c macJnetic properties. The magnetic isotropy leads to extremely low field requirements for saturation, and khe structural homogeneity allows the magnetization to reverse with extremely low fields ~i.e., a low coercive force). These two features combined with the high resistivity (15 times that of common iron) and lamination thinness provide a material with the lowest a-c losses of any known high magnetic saturation material.
Amorphous structures can be obtained by several techniques. Electroplating, vapor deposition, and sputtering are all techniques where the material is deposited on an atom by atom basis~ Under specific conditions, the atoms are frozen in place on contact and do not have a chance to move .t~D-lO~D~g to the lower energy positions o~ the normal crystal lattice sites. The resulting structure is an amorphous, non-crystalline glassy one. These methods, however~ are not economical for producing large commercial quantities.
The other method for producing amorphous structures in metals is by cooling rapidly from the liquid melt. Two conditions must be met to achieve the amorphous structure by this method. First, the composition must be selected to have a high glass transition temperature, T , and a low melting temperature, T . Specifically, the T /Tm ratio should be as large as possible. Second, the liquid must be cooled as rapidly as possible from above T to below the T . In practice, it is found that to produce metallic glasses, the cooliny rate must be of the order of a million degrees centrigade per second. Even at these high rates, only special compositions can be made amorphous. I'ypically, "glass forming" atoms such as the metalloids, phosphorus, boron, silicon, and carbon are required additions to the metal alloy, usually in the 10 to 25 atomic per cent range.
In machines, such as motors and transformers, there are design requirements on the geometry of the magnekic material. These requirements depend on the properties of the material and the physical structure of the device. Ideally, the material should be continuous along the flux path to form a completely closed magnetic circuit. This would provide the highest permeability possible for the circuit and the lowest excitation current requirements. This geometry is not possible with normal laminated electrical steel because the assembly requirements necessitate cutting the magnetic material.
For example, in transformers the negative effect on the permeability from this cutting i. partially eliminated by making a complex interleaYed joint; while in motors a 36 RD--l ~ g 4g substantial air gap remains in the magnetic ci~cuit at the interface between the rotox and stator. Another special geometric requirement on an a-c machine is that the magnetic material be thin in a plane parall~l to the flux direction.
This is essential to minimize the eddy current losses.
However, with decreasing lamination thickness, more laminations are needed so the punching time and assembly costs increase.
In accordance with the invention, an electromagnetic component is formed from a plurality of regularly spaced and aligned thin planar substantially rectangular amorphous metal ribbons positioned such that there are substantially no gaps between metal ribbons. "Substantially no gaps" means that laminae are arranged alternately whereby there is at least partial overlapping between adjacent layers or the laminae are interwoven or otherwise positioned such that there are none, i.e. the laminate is airtight and impervious to light, or contains fewer than about 20 holes per 100 sq.
inches with a hole diameter oE less than about 1/32". The ribbons can be formed into laminates by conventional means and punched or stamped into the desired shape for use in motors, transformers and other inductive componen-ts.
To form the ribbons, a stream of liquid alloy melt is delivered against a relatively rapidly moving cylindrical chill roll or other chilled surface having high thermal conductivity material, such as copper, copper alloys, steel, stainless steel, or the like. The liquid alloy is quenched and solidified and moves away from the chill cylinder to continuously form a ribbon or sheet of solidified metal. A
method for forming the ribbon i5 disclosed and claimed in i30 ~ U.S. Patent, 4,1~4,926 dated ~arch 20, 1979 -Howard H. Liebermann and assigned to the assignee of this application.

~4C~
~` ~D ~0~4g The amorphous metal ribbon being proces~e~ can ~e any of the magnetic metals. Typical materials are represented by the formula, A Z
~ Y

wherein A is one or more of Fe, Co, Ni, Mo, Wr cr and V, Z is one or more of Si, C, B, P, Al, Sn, Sbl Ge, In, and Be, x is an atomic percen-tage of from 70 to 90, and y is an atomic percentage of from 30 to 10. Typical materials are disclosed in U.S. Patent No. 3r856,513 to Chen et al - December 24, 1974.
The metal ribbons for soft magnetic properties should be at least 50 percent amorphous and preferably 90 percent or more. In order to maximize the magnetic properties, the percent by volume of magnetic material in the composite should be between about S0 percent and about 95 percent, and preferably between about 85 percent and about 95 percent.
The length of the ribbons is generally at least 1 inch and pre~erably between abouk 3 inches and about 12 inches or the length of the par-t to be ormed~ The width o~ the ribbons is generally at least 0.5 inch and preEerably at least 1 inch or the wi~th o~ the article to be formed. ~he individual laminae are generally between about 0.0005" and 0.002" thick and -the laminate at least about 4 laminae deep. Preferably, however, the laminate is greater than about 0.01" thick for best results and there is no upper limit on the thickness.
To obtain the best magnetic properties in the component or composite, the ribbons are aligned with their long axis parallel to the lines of force, in contact with one another along the axis and laying in the same plane. In some applications, however, it may be desirable to interwave the ribbon or provide laminae o~ ribbons whose long axis is parallel to the lines of force separa-ted by alternate laminae ~C~3~ RD lOg~9 of staygered ribbons of from ~bout 1 to 90. r~he r.ibbon~
can be, cor~ined with or without a binder, but pre~erably a binder is employed in some applications as it may improve the a-c electrical properties.
When a binder is employed, the amorphous ribbons can be coated by conventional means such as dipping, spraying and the like with a suitable binder, the .ribbons assembled into the desired configuration and compressed at elevated temperature and pressure until the binder softens or reacts to contain the ribbons in the compressed state.
If a binder is employed, generally from about 1 percent to about 10 percent by volume of initial constituents is sufficient and preferably from between about 1 percent and about 5 percent with a thickness less than about 0.1 mil. The pressing force will depend upon the materials and uses and the like, but generally is between about 1,000 psi and about 30,000 psi at a temperature between about 30 C and the decomposition temperature o~ the resin and the recrystallization temperature of the metal.
For best results, the ribbons will be annealed either before, during or aEter compacting, but for best results after compacting. When a binder is employed it must be able to withstand the annealing conditions. Depending upon the processing and annealing conditions and the desired end use, organic binders can he employed, such as the epoxys, polyamideimides, polyamides, polyimides, cyanoacrylates and phenolics. The binder should be electrically insulating, cure rapidly and be able to meet the thermal requirements of the intended application and annealing if required. In some applications there are further requirements, such as being compatible with cornmercial refrigerants when used for air conditioning compressor motors.

r~D lOg~g rrhe following examples will serve to illustrate the invention and preferred embodiments thereof. All parts and percentages in these examples and elsewhere in the specification and claims are by weight unless otherwise specified.
EXAMPLES
MetglasTM Alloy 2826MB ribbons 1/2 inch wide and 1.7 mils thick (manufactured by Allied Chemical Co. and having the nominal composition Fe40Ni38Mo4Bl8) were coated with a 0.2 mil film by passing through a solution of GE AI-600 polyamideimide in N-methyl pyrrolidone/hydrocarbon solvent at 7.8% solids and dried by passing through a 12' long vertical furnace at a rate of approximately 3 feet per minute with a temperature profile between 130C a-t the bottom and 240C at the top. The resultant strips were placed 6 layers deep in alternating layers at 90 in a nonmagnetic die cavity of stainless steel lined with TeflonrM-coated aluminum. The strips were easily aligne~
by means of permanent magnets placed under the die. The composite was pressed at ~000 psi and 330C Eor two minutes after allowing the die to preheat at 330C for a few minutes without pressure to equilibrate and drive out excess air and water from the die and ribbons. The composite was then tested in a d-c hysterigraph and found to have a coercive force of less than 0.01 Oe after annealing at 325C
for two hours, indicating that the composite had low hysteresis losses and that it would be useful for application in transformers and motors.
The procedure was repeated with similar results employing Metglas 2826MB one-inch wide strips.
In another experiment the amorphous metal was coated with a dilute solution (approxima-tely 10~ solids) ~ .

~ 6 RD-lo~g of Pyre-MLTM pol~imide precursor (manufactu.red by the DuPont Co.) followed by passage through the vertical fur~ace with a temperature profile between 220C and 300C. A
rigid composite - free of gaps - was then formed by bonding the aligned s-trip layers for about 3 min. at 3000 psi and 350C.
The a~ove general coating procedure was repeated with a ~urnace temperature profile between 75C and 100C
employing Butvar 74 (a polyvinyl butyral resin manu~actured by Monsanto) in ethanol solution at 10 percent solids. The -~
coated ribbons were bonded at a temperature of 125C and pressure of 1,000 psi for 3 minutes, resulting in rigid composites of laminates with laminae four deep and adhesive coats of 0.0002 inch between ribbons.
An interwoven composite was formed from MetglasTM
2826MB ribbons and impregnated with a solution of Nylon M6 in cresol at 10 percent solids. After air drying for about 15 hours at room temperature and at 200C for two hours a rigid composite was formed from a laminate with laminae fou.r deep by pressincJ at 220C and 1,000 psi for 2 minutes.
Other cores useful in transformers and stators were prepared by employing various amorphous metals and binders, with the best electrical properties achieved for composites formed of substantially all amorphous metals.

Claims

The embodiments of the invention in which an exclu-sive property or pirvilege is claimed are defined as follows:
1. A method for preparing a laminate composite for a magnetic core useful in a transformer or stator comprising the steps of assembling a plurality of thin polymer-coated metal ribbons of a magnetic metal in an applied magnetic field, said magnetic metal being at least 50 percent amorphous and having the composition represented by the formula, AxZy, wherein A is one or more Fe, Co, Ni, Mo, W, Cr, and V, Z is one or more of Si, C, B, P, Al, Sn, Sb, Ge, In, and Be, x is an atomic percentage of from 70-90, and y is an atomic percentage of from 30-10, said polymer-coated ribbons being disposed in a plurality of layers, each of said layers being composed of a plurality of said polymer-coated ribbons arranged with at least one edge of each polymer-coated ribbon contiguous with an edge of another polymer-coated ribbon and said layers being disposed relative to each other so that abutting edges in contiguous layers are covered by solid magnetic metal, simultaneously subjecting the polymer-coated ribbons so assembled to pressurization in excess of about 1000 psi and to heating to a temperature in excess of the annealing temperature and below the recrystallization temperature of said magnetic metal, and converting the annealed assembly of ribbons as required to convert said assembly into a shaped laminate suitable for construction of said magnetic core.
2. The method of claim 1 wherein the polymer present in the laminate composite is present in an amount by volume of between about 0.1 percent and about 10 percent.

3. The method of claim 1 wherein the magnetic metal is at least 90 percent amorphous.
4. The method of claim 1 wherein A is Fe and Z is B and Si.
5. The laminate composite produced by the method of
claim 1.
CA000340405A 1979-11-22 1979-11-22 Bonded amorphous metal electromagnetic components Expired CA1140036A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA000340405A CA1140036A (en) 1979-11-22 1979-11-22 Bonded amorphous metal electromagnetic components

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA000340405A CA1140036A (en) 1979-11-22 1979-11-22 Bonded amorphous metal electromagnetic components

Publications (1)

Publication Number Publication Date
CA1140036A true CA1140036A (en) 1983-01-25

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