Bulk dual phase soft magnetic components having three-dimensional magnetic flux and manufacturing methods
AssigneeGeneral Electric Company
InventorsShenyan Huang, Min Zou, Wanming Zhang
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Abstract
A bulk dual phase soft magnetic component having a three-dimensional magnetic flux and its manufacturing methods are described herein. The methods can include combining a first powder material with a second powder material to form a component structure, wherein the first powder material comprises a plurality of first particles each comprising a first core and a reactive coating, and wherein the second powder material comprises a plurality of second particles each comprising a second core and a non-reactive coating, and, consolidating the component structure to join the plurality of first particles with the plurality of second particles.
Claims19
A method for manufacturing a bulk dual phase soft magnetic component, the method comprising:
- combining a first powder material with a second powder material to form a component structure, wherein the first powder material comprises a plurality of first particles each comprising a first core and a reactive coating, and wherein the second powder material comprises a plurality of second particles each comprising a second core and a non-reactive coating, wherein the reactive coating, the non-reactive coating, or both have a thickness of 0.001 mm to 0.01 mm;
- consolidating the component structure to join the plurality of first particles with the plurality of second particles,
- wherein, subsequent to consolidating the component structure, the first core of each of the plurality of first particles is paramagnetic and comprises an iron alloy in a final austenite phase.
A method for manufacturing a bulk dual phase soft magnetic component, the method comprising:
- combining a first powder material with a second powder material to form a component structure, wherein the first powder material comprises a plurality of first particles each comprising a first core and a reactive coating, and wherein the second powder material comprises a plurality of second particles each comprising a second core and a non-reactive coating;
- consolidating the component structure to join the plurality of first particles with the plurality of second particles,
- wherein, subsequent to consolidating the component structure, the first core of each of the plurality of first particles is paramagnetic and comprises an iron alloy in a final austenite phase,
- wherein the bulk dual phase soft magnetic component comprises one or more magnetic regions, one or more non-magnetic regions, and an insulation network that extends throughout the one or more magnetic regions and the one or more non-magnetic regions.
Dependencies are inferred from the claim text.