Bulk stamped amorphous metal magnetic component

A low-loss bulk amorphous metal magnetic component comprising a plurality of similarly shaped laminations stamped from ferromagnetic amorphous metal strips, stacked and adhesively bonded together to form a polyhedrally shaped part, said amorphous metal strips having a saturation induction of at least about 1.2 tesla, and said component when operated at an excitation frequency “f” to a peak induction level Bmax has a core-loss less than “L” wherein L is given by the formula L=0.0074 f(Bmax)1.3+0.000282 f1.5(Bmax)2.4, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

A low-loss bulk amorphous metal magnetic component comprising a plurality of similarly shaped laminations stamped from ferromagnetic amorphous metal strips, stacked and adhesively bonded together to form a polyhedrally shaped part, wherein each of the amorphous metal strips has a composition defined essentially by the formula:

• M70-85 Y5-20 Z0-20, subscripts in atom percent, where “M” is at least one of Fe, Ni and Co, “Y” is at least one of B, C and P, and “Z” is at least one of Si, Al and Ge;
• with the provisos that (i) up to 10 atom percent of component “M” can be replaced with at least one of the metallic species Ti, V, Cr, Mn, Cu, Zr, Nb, Mo, Ta, Hf, Ag, Au, Pd, Pt, and W, (ii) up to 10 atom percent of components (Y+Z) can be replaced by at least one of the non-metallic species In, Sn, Sb and Pb and (iii) up to about one (1) atom percent of the components (M+Y+Z) can be incidental impurities, and wherein said component when operated at an excitation frequency “f” to a peak induction level Bmax has a core-loss less than “L” wherein L is given by the formula L=0.0074 f(Bmax)1.3+0.000282 f1.5(Bmax)2.4, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

A low-loss bulk amorphous metal magnetic component comprising a plurality of similarly shaped laminations stamped from ferromagnetic amorphous metal strips, stacked and adhesively bonded together to form a polyhedrally shaped part, wherein each of said ferromagnetic amorphous metal strips has a composition containing at least 70 atom percent Fe, at least 5 atom percent B, and at least 5 atom percent Si, with the proviso that the total content of B and Si is at least 15 atom percent, and wherein said component when operated at an excitation frequency “f” to a peak induction level Bmax has a core-loss less than “L” wherein L is given by the formula L=0.0074 f(Bmax)1.3+0.000282 f1.5(Bmax)2.4, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.