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SOFT MAGNETIC COMPOSITES

SMC materials are made of iron powder particles coated with an electrically insulating layer and can be formed into complex shapes by means of powder metallurgy, thereby allowing three-dimensional magnetic circuit design.

The intensifying electrification trend in the automotive industry along with calls for high-efficiency, low-cost industrial applications will drive the demand for energy- and cost-efficient electromagnetic components. Soft Magnetic Composite (SMC) materials play a fundamental role in this conversion, making it possible to manufacture more compact and cost-efficient motor and inductor solutions compared to using traditional designs.

The main benefits of SMC solutions for both motor design and production  processes are:

• Compact design – both size and weight of the components can be reduced

• High performance – can meet the highest efficiency requirements

• Excellent cost efficiency – the compact designs require less material and enable simple net shaping production process with minimum waste and reduced need for subsequent operations.

Our Soft Magnetic Composites can be used in a wide range of different applications such as:

Sintered-soft-magnetics-SMC-composite-components

SMC (Soft Magnetic Composite) V Traditional Laminated Steel

The traditional lamination (electrical) steel motor construction is being challenged by the emergence of powder metal parts made from soft magnetic composite.

Magnetism: Soft Magnetic Composite Vs. Laminated Steel

Magnetic properties depend strongly on the manufacturing process.

For laminations, the manufacturing process can include:

  • Punching
  • Stacking
  • Welding
  • Riveting
  • Pressing

Each of the above processes deforms the interior of the material, resulting in weaker magnetic properties.

Because ferromagnetic materials (like SMCs) have a different structure, you’ll see a different distribution of magnetic losses in them.

For example, the hysteresis losses (energy wasted in by heat loss) in SMCs are higher,  BUT, eddy current losses are much lower in soft magnetic composites.  Their eddy losses are lower because the tiny composite particles are so isolated.

2D of Laminated Vs. 3D of SMC’s

Steel laminate motor construction is limited to 2D magnetic flux so you don’t lose too much magnetism in the direction perpendicular to the laminate.

However. because soft magnetic powder composites create a 3D magnetic flux path, design options increase greatly.

SMC material’s makeup combined with its net shaping capability allow you to introduce new 3D solutions with minimal iron (magnetic) loss and optimized copper winding. Even a standard motor’s performance and capabilities can be upgraded through the design options presented by SMC .

Automotive

  • Traction motors
  • Air conditioning compressors
  • Pumps (cooling, oil, etc.)
  • DC/DC converters
  • On-vehicle chargers

Industrial

  •  Air conditioning compressors
  • Ventilation fans
  • Solar power
  • Industrial motor drives
  • Off-board battery charging

The SMC materials are developed for component manufacturing of electromagnetic applications, providing high performance and low losses. They are designed for efficient volume production at low cost, by utilising state-of-the-art technology. It is the 3D magnetic properties and the net shaping capabilities of the SMC materials that open up new opportunities to design compact, light and cost-efficient solutions.

Examples of how SMC materials can provide lower production costs:

  • Size and weight reduction of components
  • Reduction of the total number of parts in the final application
  • Less need for machining
  • Low scrap rate in manufacturing

Material Benefits:

  • High resistivity
  • High flux density
  • Tight tolerances achievable
  • Low core losses at High frequencies
  • High permeability
  • 3D flux paths
  • Net shape capability