Iron-Silicon (Fe-Si ) Powder Cores

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1 Iron-Silicon (Fe-Si ) Powder Cores INTRODUCTION Arnold Magnetics, a world leader in magnetic alloy powder products such as MPP, High- Flux and Super-MSS, now offers a new series of powder cores using an Iron-Silicon alloy under the trade name Fe-Si. The 6.5 wt% Iron-Silicon material is a well known alloy and offers significant advantages, displaying excellent soft magnetic properties such as high saturation magnetization, near zero magnetostriction and higher resistivity. The Fe-Si series powder cores are manufactured from a complex composition of Iron-Silicon powdered particles, compacted into geometries such as toroid, block, E or U- core shapes. The powder metal compaction process produces a product with excellent core loss performance compared with the conventional silicon-iron tape wound core due to the distributed air gap feature. Fe-Si powder cores have a typical 5,000 Gauss saturation flux density and core losses significantly lower than iron powder cores at high frequencies. The combination of high saturation flux density and high DC bias makes Iron-Silicon powder cores an ideal choice for higher power densities: where a low number of winding turns, low core loss and smaller size are required in today's power supply systems - especially in high energy storage applications. The curie temperature of the Iron-Silicon powder material is over 500 ºC. High temperature operation of the cores does not significantly affect the magnetic properties. There are no organic binders within Fe-Si cores. They are, therefore, not subject to thermal aging when operated at elevated temperatures. Fe-Si series cores can provide a 30% reduction in volume compared to Iron powder cores and are the best solution for large-current applications at a competitive price. General Material Properties Composition Iron-Silicon Alloy Material Code FS Permeability 4μ to 47μ Bmax 5,000 Gauss Core Loss (,000 G, ) mw/cc Curie Temperature 500 ºC Operating Temperature -30 to 200 ºC Frequency Range MHz Relative Cost Low

2 Typical Applications SMPS choke inductors PFC inductors VRM inductors Boost reactor Smoothing choke for Inverter Switching Regulator Inductors In Line Noise Filters >50 KVA UPS choke inductors Benefits High saturation flux density Very high DC biasing Performance Lower cost than SMSS or similar materials Manufactured into various shapes (e.g. E, U, toroid, block cores) Maximum operating temperature of 200 C The DC bias curves (below) demonstrate that Iron-Silicon powder is excellent when compared with SMSS (Sendust) and Iron powder of similar permeabilities and size. The curves presented here were measured based on standard.06 inch OD toroid core samples using a signal of khz and ma AC µ Percent Permeability DC Bias 75μ 90μ μ 60μ 0 0 DC Magnetizing Force (Oersteds)

3 The inductance versus frequency graph demonstrates the near linear performance of Iron- Silicon powder cores to MHz. Roll-off in permeability from low frequencies to MHz is less than 2.0 percent! Fe-Si Permeability μ 25μ 90μ 75μ 60μ μ 4μ 0 0 Frequency (khz) Permeability versus Temperature Arnold Fe-Si cores are extremely stable with temperature. % Permiability versus Temperature 8% 6% Permiability, % 4% 2% 0% -2% -4% FS 25μ FS 60μ FS 26μ -6% -8% -% Temperature, ºC

4 Typical Core Loss Curves 0 Fe-Si 4μ 0 Fe-Si 26μ 300KHZ khz 2 khz khz 2 khz khz khz Fe-Si 60μ 0 Fe-Si 75μ khz 2 khz khz khz 2 khz KHZ Fe-Si 90μ 0 Fe-Si 25μ khz khz 2 khz khz 2 khz khz Fe-Si 47μ khz 2 khz khz 0 00

5 Toroid Core Part Number Construction Part numbers for Arnold Fe-Si TM cores are constructed as shown below. FS Iron-Silicon (Fe-Si ) Toroidal Core Series Size table O.D.(inch) I.D.(inch) HGT(inch) Radius(inch) Area (cm 2 ) Lm (cm) Volume (cm 3 ) Arnold Magnetics can supply a wide range of standard toroid O.D. sizes from 4 inch (3.6 mm) to 5.28 inch (33 mm), as with Arnold MPP, High-Flux and Super-MSS powder core series. Arnold is also capable of providing non-standard, customer-specified physical dimensions.

6 E-Core Part Number Construction B C L A F M E D Iron-Silicon (Fe-Si ) E-Core Series Size table PART NO. UNIT A B C D(min) E(min) F L(nom) M(min) EFS- in 0.500± ± ± ± (mm) (2.70) (6.40) (3.56) (4.42) (8.89) (3.56) (.78) (2.64) EFS- in 0.760± ± ± ± (mm) (9.30) (8.) (4.78) (5.54) (3.90) (4.78) (2.39) (4.65) EFS- in.000± ± ± ± (mm) (25.40) (9.50) (6.50) (6.20) (8.80) (6.20) (3.20) (6.30) EFS- in.85± ± ± ± (mm) (30.) (5.0) (7.06) (9.70) (9.50) (6.96) (5.) (6.46) EFS- in.360± ± ± ± (mm) (34.50) (4.) (9.40) (9.60) (25.30) (9.30) (4.40) (7.90) EFS- in.609± ± ± ± (mm) (40.90) (6.50) (2.50) (.40) (28.30) (2.50) (6.00) (7.90) EFS- in.687± ± ± ± (mm) (42.80) (2.) (.80) (5.00) (30.40) (.90) (5.95) (9.27) EFS- in.687± ± ± ± (mm) (42.80) (2.) (5.40) (5.00) (30.40) (.90) (5.95) (9.27) EFS- in.687± ± ± ± (mm) (42.80) (2.) (20.00) (5.00) (30.40) (.90) (5.95) (9.27) Add material code to part number, e.g., for 60µ the complete part number is EFS Arnold is also capable of providing non-standard; customer-specified physical dimensions and geometries for E, U and block cores. Arnold Magnetics Limited D6 Xintang Industrial Zone Baishixia, Fuyong Town Baoan, Shenzhen, Guangdong, PRC For more information contact us at: UNITED STATES Rochester, NY USA EUROPE Barlborough, UK (+44) ASIA Hong Kong, China (+852)