SBIR Phase I: Technique for Low Cost Fabrication of Amorphous Magnetic Material for Electric Power Applications

这个小型企业创新研究（SBIR）一期项目旨在研究一种制造块状非晶磁性材料的新方法。这种方法是基于一种新型的热喷涂方法，用于净或近净成形，该方法已证明能够实现保持非晶态所需的高热淬火速率。非晶磁性材料是低损耗电力电子应用的理想材料，如变压器的铁芯。不幸的是，目前非晶铁芯变压器的制造成本超过了晶粒取向硅钢的竞争技术成本。这项研究的目的是证明该概念作为一种可替代的、节省成本的制造方法的可行性，并为第二阶段项目做准备，以进一步开发该技术，并更全面地了解该方法的优点和局限性。该项目的商业潜力是巨大的，因为仅变压器铁芯损耗就占每年数十亿美元的损失范围，而非晶铁芯变压器已经实现了大幅度的损耗降低。制造过程中任何成本的降低都将促进进一步的市场渗透和更有效的配电网络。

This Small Business Innovation Research (SBIR) Phase I Project is aimed at investigating a new method for fabrication of bulk amorphous magnetic material. This method is based on a novel thermal spray approach for net or near-net shaping that has demonstrated the capability to achieve the high thermal quench rates that are necessary for retention of the amorphous state. Amorphous magnetic material is desirable for low-loss power electronic applications such as the core of electrical transformers. Unfortunately, manufacturing costs of amorphous core transformers presently exceeds the costs of the competing technology of grain oriented silicon steel. It is the intent of this research to demonstrate the feasibility of the concept as an alternative and cost-saving fabrication method and to prepare for a Phase II project to further develop the technology and gain a more complete understanding of the advantages and limitations of the approach.The commercial potential of the project is significant in that transformer core losses alone account for annual losses in the range of billions of dollars, and amorphous core transformers already realize substantial loss reduction. Any cost reduction in the manufacturing process would promote further market penetration and a more efficient power distribution network.