Insulated Powder Composites Brochure.QXD (Page 3) - GKN

HOEGANAES 

INSULATED POWDER COMPOSITES 

CHARACTERISTICS AND ELECTROMAGNETIC 

APPLICATION GUIDELINES

HOEGANAES 


INTRODUCTION 

The molecular field theory was developed nearly 

100 years ago. At that time, it was explained that 

groups of iron atoms are magnetized in one 

direction with equal groups of atoms magnetized 

in the opposite direction, thus fully compensating 

each other with zero net magnetic moment. 

These groups of atoms are referred to as 

magnetic domains. In a given iron powder 

particle, there are a substantial number of 

domains all arranged in a way to give a zero 

magnetic moment. Extremely fine particles can 

potentially represent single domain structures. 

Lodestone happens to be a natural, single domain 

iron ore (magnetite), which exhibits intrinsic 

permanent magnet characteristics. Its discovery 

had a significant impact on the history of the 

world. The development of Insulated Powder 

Composites represents the next step toward 

further advancement in soft magnetic material 

systems! 

BENEFITS OF THE POWDER 

METALLURGY PROCESS 

• Net Shape Capability 

• Complex Shapes 

• Engineered Materials 

• High Production Rates 

• Tolerance Control 

• Good Surface Finish 

BENEFITS OF INSULATED 

POWDER MATERIALS 

• Isotropic magnetic structure permits 

3-dimensional magnetic 

flux path capability 

• Easily shaped into complex 

configurations using 

conventional powder 

metallurgy compaction 

process 

• Similar magnetic saturation 

induction values to wrought 

steel laminations 

• Low inherent eddy current 

losses associated with the 

dielectric polymer coating 

• Flexibility to engineer 

performance characteristics 

to satisfy application 

requirements 

• Preferred alternative to 

laminations for new electric 

motor designs

APPLICATIONS CHART 

For switching actuators and ignition coils, fuel injectors, 

motor applications 

Resistivity Strength Induction B Permeability 

microohm-meter 

(MPa) 10 kA/m (T) Max 

Ancorlam >50 90 1.47 470 

Ancorlam HR >1300 60 1.52 400 

Ancorlam 2HR* >475 90 1.64 610 

For higher frequency applications, power electronics 




Ancorlam 2FHR >1300 60 1.51 360 

Ancorlam HR >1300 60 1.51 400 

For motor applications requiring high induction and 

permeability, actuators, frequencies up to 400 Hz 




Ancorlam 2 50 50 1.60 550 

Ancorlam 2HR* 475 90 1.64 610 

*Density of 7.6 g/cm 3 

Grade modification is possible to meet application 

specific properties 

CONVERSIONS / CALCULATIONS 

1 Tesla = Gauss X 10 -4 

1 Tesla = 1 Weber per meter 2 

1 Gauss = 1 Maxwell per cm 2 

Amp-Turns per meter = Oersteds x 79.5 (1 Amp-Turn per meter = 0.0125 Oe) 

Tesla/Meter = Gauss x 1.26 10 -6 

Amp-Turns Oersted 

Frequency = 

rpm x Number of Poles (rotating electrical devices) 

120 

Inductance = L = 4πµA 

N 2 I 

L = Inductance (mH) 

µ = Permeability 

A = Cross-sectional area (cm 2 ) 

I = Path length (cm) 

N = Number of turns 

POWDER METALLURGY 

PROCESSES FOR 

ELECTROMAGNETIC GRADES 

Composite Production: 

Admix Metal Powder, Additives, 

Coating Materials 

Press Ready 

Insulated Powder Composite 

Material 

Cold or Warm Compaction 

Optional 

Secondary Curing or Stress 

Relieving 

Optional Finishing Processes: 

Machining 

Polymer Impregnation 

Plating 

Finished Electromagnetic 

Component 

100µm 

Microstructure illustrating insulative coating

HOEGANAES 


Iron powders exposed to a magnetic field 

gradually begin to realign the individual 

domains by slowly orienting themselves toward 

the direction of the applied magnetic field. 

When the magnetic field is switched off, the 

domains remain partially oriented in the original 

magnetic direction. Zero magnetism is realized 

when the reverse field equals the coercive 

force. With further increases in the reverse field, 

the domains revert to the new direction. 

The field required to reverse the domain 

depends upon the crystalline symmetry and 

anisotropic properties. This energy is very small 

in the case of a soft magnetic material, and 

considerably greater for a hard magnetic 

material, i.e., types that maintain high 

remanence, typically referred to as permanent 

magnets. 

The most commonly used soft magnetic 

material involves electrical steel laminations for 

low frequency (60 – 200 Hz) applications. 

Low-end performance materials include 

cold-rolled, motor lamination steels, whereas 

intermediate to high-end characteristics are 

achieved with silicon-iron, or oriented steels. 

Laminations are prevalent because of existing 

design familiarity, relatively low costs and 

adequate magnetic performance. Nevertheless, 

the limited two-dimensional flux path capability 

and relatively low energy efficiency at higher 

operating frequency make them undesirable for 

new electric motor designs. 


The introduction of uniformly coated iron 

particles providing a three-dimensional 

distributed air gap with an isotropic flux path, 

allows designers to reconsider conventional 

topology restrictions typical of steel 

laminations. Along with the benefits of PM net 

shape manufacturing capability, insulated 

composite materials exhibit inherently low 

eddy current losses even when subjected to 

operating frequencies exceeding 400 Hz. 

Composite manufacturing flexibility provides 

the ability to engineer soft magnetic 

characteristics to suit specific application 

requirements. Incorporating different iron 

powder size distributions, and coating types to 

increase resistivity, various attributes can be 

manipulated to enhance the material’s 

permeability, structural density or core-loss 

characteristics. 

Coupling new electrical device design 

topologies with insulated powder composites 

and high-energy permanent magnets provides 

the necessary performance enhancements 

along with concurrent improvements in 

component efficiency, packaging and simplified 

manufacturing processes. The additional 

magnetizing force (mmf) of the permanent 

magnet compensates for the lower permeability 

of the soft magnetic composite grades. 

The complementary materials and new designs 

provide greater performance and enhanced 

efficiency, with the ability to reduce 

manufacturing costs and component 

package size. 

Applications for these magnetic materials 

include high-efficiency electric motors, 

high-frequency transformers, and unique 

electrical components. The electrical design 

engineer has three-dimensional shape-making 

flexibility plus the high material utilization 

inherent with the PM process. Design flexibility 

is enhanced further by the ability to bond 

together small segments to form larger, more 

complex shapes.

INSULATED POWDER COMPOSITE PERFORMANCE 

AncorLam 

AncorLam HR 

AncorLam 2F HR 

Compacting pressure (MPa) 830 830 830 830 830 

Powder temp. ( o C) RT RT RT RT RT 

Tool temp. ( o C) 80 80 80 80 80 

Curing temp. ( o C) >300 >300 >300 >300 >300 

Cured density 7.47 7.45 7.6 7.43 7.5 

Induction B @ 10 kA/m (T) 1.47 1.52 1.64 1.5 1.6 

Permeability at 60 Hz 470 370 610 360 550 

Resistivity, micro-ohm-meter >50 >1300 >500 >1300 >50 

Coercive field strength (A/m) 300 270 246 280 245 

Strength (MPa) 90 60 90 60 40 

Core-loss @ 1T (watts/kg) 

AncorLam 2 HR 

60 Hz 9 7.6 6.6 7.3 9 

100 Hz 15 13 11.2 13.5 15 

200 Hz 31 27 24 27 31 

400 Hz 67 53 52 54 67 

1000 Hz - 147 172 146 245 

AncorLam 2 

All properties improve with higher compaction pressures(density), especially induction, permeability and core-loss. 

Insulated Powder Composite manufacturing flexibility provides the ability to engineer soft 

magnetic characteristics to suit specific application requirements. Incorporating different iron 

powder size distributions and coating types to increase bulk resistivity various attributes can be 

manipulated to enhance the material’s structural density, induction, permeability or core-loss 

characteristics. 

Grade modification is possible to meet application specific properties.

AncorLam ® 

Induction in Tesla 

AncorLam ® is a high performance insulated powder material suitable for a variety of soft magnetic 

applications. Specific applications include switching actuators and ignition coils, fuel injectors, and 

motor applications. 

AncorLam ® consists of high purity iron powder with a specialized coating/lubricant system that 

minimizes hysteresis and eddy current losses over a range of frequencies. This material is provided 

as a press-ready premix for warm or cold die compaction. 

AncorLam is a lower cost option giving good balance between Core Loss and Induction. 

Performance of AncorLam ® at 7.45 g/cm 3 

Induction at 40 kA/m (T) 1.90 


Maximum permeability 470 

Coercive field strength (A/m) 300 

Core-loss at 400 Hz, 1T, W/kg 67 

Core-loss 1 kHz, 1T, W/kg — 

Green density (g/cm3 ) 7.47 

Cured strength (MPa) 90 

Resistivity micro-ohm-meter >50 

Apparent density (g/cm3 ) 2.85-3.10 

Hall flow (s/50 g) 32 max 

HYSTERESIS LOOP 

AncorLam 

2.5 

2 

1.5 

1 

0.5 

0 

-5000 -4000 -3000 -2000 -1000 0 1000 2000 3000 4000 5000 

-0.5 

-1 

-1.5 

-2 

-2.5 

Applied Field in A/m

AncorLam ® (continued) 

Core-loss in Watts/kg 


10000 

1000 

100 

0.1 

0.01 

500 

450 

400 

350 

300 

250 

200 

150 

100 

50 

10 

1 

CORE-LOSS VS. INDUCTION 

60 Hz, 100 Hz, 200 Hz, 400 Hz, 1k Hz, 5k Hz, 10 kHz 

0.001 

0.001 0.01 0.1 


1 10 

PERMEABILITY VS. INDUCTION, FREQUENCY 

60 Hz, 100 Hz, 200 Hz, 400 Hz, 1000 Hz, 5000 Hz 

5000 Hz 

10 kHz 

0 

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 

60 Hz 


60 Hz 

10 kHz 

5 kHz 

1 kHz 

400 Hz 

200 Hz 

100 Hz 

60 Hz

AncorLam ® HR 


AncorLam ® HR has a constant permeability over a wide frequency range providing a lower cost 

option for high frequency applications. 

AncorLam ® HR consists of high purity iron powder with a specialized coating/lubricant system that 


as a press ready premix for warm or cold die compaction. 

Performance of AncorLam ® HR at 7.45 g/cm 3 






Core-loss 1 kHz, 1T, W/kg 147 







AncorLam HR 

2.5 

2 

1.5 

1 

0.5 

0 

-5000 -4000 -3000 -2000 -1000 0 1000 2000 3000 4000 5000 

-0.5 

-1 

-1.5 

-2 

-2.5 


AncorLam ® HR (continued) 


Permeability 

10000 

1000 

400 

350 

300 

250 

200 

150 

100 

50 

100 

0 

10 

0.0001 

1 

0.1 

0.01 

0.001 

CORE-LOSS AT VARIOUS FREQUENCIES AND INDUCTION 

60 Hz, 100 Hz, 200 Hz, 400 Hz, 1000 Hz, 5000 Hz, 10000 Hz 

0.001 0.01 0.1 1 10 

PERMEABILITY AT VARIOUS FREQUENCIES 


10000 Hz 


0 0.4 0.8 1.2 1.6 2 


60 Hz 

10 kHz 

5 kHz 

1 kHz 

400 Hz 

200 Hz 

100 Hz 

60 Hz

AncorLam ® 2HR 


AncorLam ® 2 HR is bested suited for motor and actuator applications. Providing good induction and 

permeability for applications up to 1000 HZ. 

AncorLam ® 2 HR consists of high purity iron powder with a specialized coating/lubricant system that 

increase permeability while limiting losses. This material is provided as a press ready premix for 

warm or cold die compaction. 

Performance of AncorLam ® 2HR 

Induction at 40 kA/m (T) 2.02* 

Induction at 10 kA/m (T) 1.64* 

Maximum permeability 610* 

Coercive field strength (A/m) 246* 

Core-loss at 400 Hz, 1T, W/kg 52* 

Core-loss 1 kHz, 1T, W/kg 172* 

Green density (g/cm3 ) 7.60* 

Cured strength (MPa) 90* 

Resistivity micro-ohm-meter >475* 

Apparent density (g/cm3 ) 2.85-3.10* 

Hall flow (s/50 g) 

* Density is 7.6 g.cm 

32 max* 

3 


AncorLam 2HR*(7.6 DENSITY) 

2.5 

2 

1.5 

1 

0.5 

0 

-10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000 

-0.5 

-1 

-1.5 

-2 

-2.5 


AncorLam ® 2HR (continued) 


Permeability 

10000 

1000 

100 

10 

1 

0.1 

0.01 

0.001 

700 

600 

500 

400 

300 

200 

100 

0 

CORE-LOSS VS INDUCTION (7.6 DENSITY) 


0.0001 

0.01 0.1 1 10 


PERMEABILITY VS INDUCTION (7.6 DENSITY) 

60 Hz, 100 Hz, 400 Hz, 1000 Hz, 5000 Hz, 10000 Hz 

60 Hz 

10 kHz 

0 0.5 1 1.5 2 2.5 


10 kHz 

5 kHz 

1 kHz 

400 Hz 

200 Hz 

100 Hz 

60 Hz

AncorLam ® 2FHR 


AncorLam ® 2FHR is targeted and engineered for higher frequency applications up to 31 Khz. 

AncorLam ® 2FHR consists of high purity iron powder with a specialized coating/lubricant system that 


as a press ready premix for warm or cold die compaction. 

Performance of Ancorlam ® 2FHR at 7.45 g/cm 3 





Core-loss at 400Hz, 1T, W/kg 54 

Core-loss 1kHz, 1T, W/kg 146 







AncorLam 2FHR 

2.5 

2 

1.5 

1 

0.5 

0 

-5000 -4000 -3000 -2000 -1000 0 1000 2000 3000 4000 5000 

-0.5 

-1 

-1.5 

-2 

-2.5 


AncorLam ® 2FHR (continued) 


Permeability 

10000 

1000 

100 

10 

1 

0.1 

0.01 

400 

350 

300 

250 

200 

150 

100 

50 

0 

CORE-LOSS AT VARIOUS FREQUENCIES 


0.001 

0.001 0.01 0.1 1 10 

PERMEABILITY AT VARIOUS FREQUENCIES AND INDUCTION 


10000 Hz 


0 0.4 0.8 1.2 1.6 2 


60 Hz 

10 kHz 

5 kHz 

1 kHz 

400 Hz 

200 Hz 

100 Hz 

60 Hz

AncorLam ® 2 

AncorLam ® 2 is a high performance insulated powder material suitable for a variety of soft magnetic 

applications that require high permeability. Used for applications up to 400 HZ. 

Performance of AncorLam ® 2 at 7.45 g/cm 3 






Core-loss 1 kHz, 1T, W/kg 245 







DC HYSTERESIS LOOP 

AncorLam 2 

2.5 

2 

1.5 

1 

0.5 

0 

-5000 -4000 -3000 -2000 -1000 0 1000 2000 3000 4000 5000 

-0.5 

-1 

-1.5 

Applied Field in A/m 

-2 

-2.5 


AncorLam ® 2 (continued) 


Permeability 

10000 

1000 

600 

500 

400 

300 

200 

100 

100 

10 

1 

0.1 

0.01 

CORE-LOSS AT VARIOUS FREQUENCIES 


0.001 

0.001 0.01 0.1 1 10 

AC PERMEABILITY 


10000 Hz 


0 

0 0.5 1 1.5 2 2.5 

60 Hz 


10 kHz 

5 kHz 

1 kHz 

400 Hz 

200 Hz 

100 Hz 

60 Hz

RELEVANCE OF MATERIAL CHARACTERISTICS ON END-USE 

PERFORMANCE FOR ELECTROMAGNETIC DEVICES 

Permeability Influences the output power of 

the electrical device. Wrought lamination stacks 

represent two-dimensional values typically 

ranging between 1500 and 5000, whereas the 

isotropic IP grades approach ~500 permeability. 

Some conversions may necessitate higher input 

current to achieve similar flux density. However, 

3-dimensional flux paths provide greater design 

and performance flexibility. In addition, use of 

high-energy permanent magnet materials can 

compensate for the lower permeability of the 

soft magnetic composite grades. 

Induction Influences the ultimate torque 

capability of rotating machines. Lower values 

can be offset by increasing the backing section 

(material mass), while maintaining optimal 

component packaging associated with 

optimized end-winding and slot fill. 

Strength In some instances, components must 

withstand rotational forces, stresses associated 

with press fitting or compression joining, and 

have sufficient strength to accommodate the 

copper winding process during assembly. 

Appropriate polymer types and process 

conditions permit adequate strength to support 

application requirements. 

AC Frequency Preferred applications involve 

operating conditions of 200 Hz electrical 

frequency. This utilizes the benefits associated 

with the inherently low eddy current losses of 

I.P. materials. 

Core-Loss The two primary components of 

core-loss include eddy current and hysteresis 

losses. Greater core-loss values generally 

increase operating temperatures, which leads to 

additional losses. Lower loss values translate 

into greater electrical efficiencies. Losses can be 

minimized with proper particle coating, binder 

combinations and stress relief. 

Processing Conditions Various options exist 

depending upon the binder and/or lubricant 

combinations. Warm compaction, with or 

without powder heating, or conventional 

compaction can be used for a variety of 

applications. 

Base Iron Chemical composition and particle 

size, along with component density, can be 

manipulated to enhance specific magnetic 

performance characteristics. 

Curing Temperature A secondary thermal 

treatment enhances the binder strength and 

helps minimize internal stress promoting 

recovery of the iron powder crystal structure. 

Temperature optimization is required to limit 

internal stresses without destroying the binder 

characteristics.

MAGNETIC TERMINOLOGY 

Induction (B) is the magnetic flux per unit area, 

measured in Gauss. Sometimes referred to as 

flux density. This characteristic has a direct 

relationship with component density. 

Permeability (µ) essentially indicates the ease 

with which a material can be magnetized or its 

magnetic sensitivity – represents a ratio of flux 

density to magnetizing force. 

Coercive Field Strength (Hc ) is the 

demagnetizing force necessary to restore the 

magnetic induction to zero. 

Eddy Current Loss is the primary component 

of high frequency loss. Generally associated 

with electrical currents that create an opposing 

force to the magnetic flux when exposed to AC 

fields. Higher resistivity values are beneficial in 

minimizing eddy current losses. 

Hysteresis Loss represents the primary loss 

factor at lower frequency, and is primarily 

attributed to magnetic friction in the core. Wider 

and taller B-H loop areas generally represent 

greater hysteresis loss for a given material. 

Intrinsic Saturation is the point at which all the 

domains in the magnetic material become 

oriented in the same direction as the applied 

field energy. 

Magnetizing Force (H) is the applied energy to 

induce magnetic flux, measured in Oersteds. 

Hysteresis Curve is the measurement technique 

representing the closed circuit of a magnetic 

material subjected to positive and negative 

magnetizing forces – graphically represents 

the material’s magnetic characterization, 

i.e., saturation, residual induction and coercive 

field strength. 

Soft Magnetic components have the ability to 

both store or strengthen magnetic energy and 

allow for easy conversion back into electrical 

energy - often utilized to strengthen the 

magnetic flux of an electric device as a core 

product. 

Hard Magnets represent greater coercivity 

levels and are difficult to demagnetize, typically 

referred to as permanent magnets and 

represent a broad B-H curve band-width 

(>M.M.F.). 

Air Gap represents a low permeability gap 

(air space) in the flux path of a magnetic circuit, 

generally undesirable for energy transfer – 

however, can be beneficial to increase the 

ability to store energy in a core. 

Reluctance essentially represents magnetic 

circuit “resistance,” which is inversely 

proportional to permeability and directly 

proportional to magnetic circuit length. 

Ferrites are combinations of iron oxides with 

Mn, Zn, Ni used when high permeability and 

low eddy current losses are desirable, generally 

exhibit low saturation induction – generally used 

for high frequency 10 KHz to 1 GHz applications. 

Laminations are low carbon steel or silicon-iron 

grades made in thin strips with insulation 

coating positioned between layered stacks, 

extensively used in low 60 Hz electric motor 

applications because of low cost and design 

familiarity. 

Iron Powder Cores share some characteristics 

with Insulated Powder grades. They are 

primarily used for energy storage, transformers 

and inductors in various consumer products. 

Q Factor is a means of determining the 

effectiveness of an iron core – represents a ratio 

of the increase in effective inductance to the 

increase in the equivalent resistance of the 

magnetic circuit: Q = I / R (I= increase in test 

coil inductance, R = core-losses). 

Hysteresis curve 

representative 

of a soft magnet 

material

Hoeganaes Corporation 

1001 Taylors Lane 

Cinnaminson, NJ 08077-2017 

Phone: 856.829.2220 • Fax: 856.786.2574 

www.hoeganaes.com 

© 2010 Hoeganaes Corp. All Rights Reserved. Form HEG-750-P

Insulated Powder Composites Brochure.QXD (Page 3) - GKN

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