Low core loss, well-bonded soft magnetic parts

A stator for an alternating current generator comprising a plurality of ferromagnetic particles consolidated in a shape of a stator core, said shape comprising an annular yoke and a plurality of integral inner circumferentially spaced projections radiating and extending inwardly and defining slots, each of said ferromagnetic particles having coated thereon an oxide-phosphate material that has an electrical insulation value that does not degrade at temperatures above 150.degree. C., said core having an as consolidated transverse rupture strength, as determined in accordance with MPIF (Metal Powders Industry Foundation) Standard 41, of at least about 8 Kpsi.

A rotor for an alternating current generator comprising:

• a plurality of ferromagnetic particles consolidated in a shape of an elongated annular shaped cylinder defining a cylindrical void through which passes an elongated cylindrical shaft for rotating said rotor, each of said ferromagnetic particles having coated thereon an oxide-phosphate material that has an electrical insulation value that does not degrade at temperatures above 150.degree. C., said rotor having an as consolidated transverse rupture strength, as determined in accordance with MPIF (Metal Powders Industry Foundation) Standard 41, of at least about 8 kpsi.

An armature assembly for an alternating current generator comprising a plurality of ferromagnetic particles consolidated in a shape of an armature core and a shaft for rotating said armature core, said shape comprising an elongated annular shaped cylinder defining an elongated cylindrical void through which the shaft passes, said annular shaped cylinder having a plurality of troughs at spaced intervals extending lengthwise along an exterior surface thereof, each of said ferromagnetic particles having coated thereon an oxide-phosphate material that has an electrical insulation value that does not degrade at temperatures above 150.degree. C., said core having an as consolidated transverse rupture strength, as determined in accordance with MPIF (Metal Powders Industry Foundation) Standard 41, of at least about 8 kpsi.

An armature assembly for an alternating current generator comprising a plurality of ferromagnetic particles consolidated in a shape of an armature core and a shaft for rotating said armature core, said shape comprising an elongated annular shaped cylinder defining an elongated cylindrical void through which the shaft passes, said annular shaped cylinder having a plurality of troughs at spaced intervals extending lengthwise along an exterior surface thereof, each of said ferromagnetic particles having coated thereon a material comprising from about 50% to about 85% by weight of a member selected from the group consisting of FeO, Fe.sub.3 O.sub.4, Fe.sub.2 O.sub.3, (Fe.sub.2 O.sub.3 .cndot.H.sub.2 O) and combinations thereof;

• and from about 15% to about 50% by weight of a member selected from the group consisting of FePO.sub.4, Fe.sub.3 (PO.sub.4).sub.2, FeHPO.sub.4, Fe.sub.3 (PO.sub.4).sub.2 .cndot.2H.sub.2 O, Fe.sub.2 (PO.sub.4).sub.3 .cndot.8H.sub.2 O, and combinations thereof, said material having an electrical insulation value that does not degrade at temperatures above 150.degree. C., said core having an as consolidated transverse rupture strength, as determined in accordance with MPIF (Metal Powders Industry Foundation) Standard 41, of at least about 8 kpsi.

A rotor for an alternating current generator comprising:

• a plurality of ferromagnetic particles consolidated in a shape of an elongated annular shared cylinder defining a cylindrical void through which passes an elongated cylindrical shaft for rotating said rotor, each of said ferromagnetic particles having coated thereon a material comprising from about 50% to about 85% by weight of a member selected from the group consisting of FeO, Fe.sub.3 O.sub.4, Fe.sub.2 O.sub.3, (Fe.sub.2 O.sub.3 .cndot.H.sub.2 O) and combinations thereof;
• and from about 15% to about 50% by weight of a member selected from the group consisting of FePO.sub.4, Fe.sub.3 (PO.sub.4).sub.2, FeHPO.sub.4, Fe.sub.3 (PO.sub.4).sub.2 .cndot.2H.sub.2 O, Fe.sub.2 (PO.sub.4).sub.3 .cndot.8H.sub.2 O, and combinations thereof, said material having an electrical insulation value that does not degrade at temperatures above 150.degree. C., said rotor having an as consolidated transverse rupture strength, as determined in accordance with MPIF (Metal Powders Industry Foundation) Standard 41, of at least about 8 kpsi.