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Ultra-low Core Loss Magnetic Material Technology Area
  • OUTLINE
  • RESEARCH CONTENTE
  • SHARED EQUIPMENTE

OUTLINE

It is anticipated that the application of the superior soft magnetic materials in the fields from an electricity transport to appliances contributes to the reduction of the world energy consumptions. The core loss (energy loss) arisen from the transduction from electricity to magnetic in the magnetic products was 3.4% of the overall electrical consumption in the world.
On the other hand, the iron-silicon magnetic products, having a proportion of 96% among the transformers and motors products, seem to reach their limitation in the aspects of magnetic performance as core materials.
The ultra-low core loss of innovative high-Fe soft magnetic materials with a self-organizing nanoheteromorphous structure developed by Tohoku University have a great potential for further reducing the core loss. Facing and solving new energy issues it is of necessary for developing the superior nanocrystalline soft magnetic alloys.

In order to solve technical issues involved during commercializing innovative soft magnetic materials, the new basic technologies for the material development is required from the basis of expertise and academic disciplines. New design guidelines, cultivate new professional human resources, and a new research and development scheme that facilitates dialogue on common problems between scholars and engineers from different disciplines is aimed to be constructed, particularly, in research on elemental technology the basis for research on magnetism, nanostructure control, and metallic engineering.

In the field of nano-crystalline soft magnetic materials essential material design guidelines are to be made to integrate research on magnetism and theories of organizational structure, and thus advance the development of this field of research.
Furthermore, the multi-faceted collaboration between government, industry and academia motivated by this research initiative could foster the development of industries in the Tohoku region. Together with the Ministry of Economy, Trade and Industry new schemes of cooperation is created to bring together material producers, industry, academia and government as incubators and mass-producers. Moreover, we create a system that involves cooperation with producers that apply magnetic materials.
The commercialization of these ribbon products for transformers or fine powder products for motors as new materials is highly anticipated to further reduce the energy loss in the power-magnetism transduction more than 25% until 2016. The technology developed by this project is to be actively provided to affiliate companies in the Tohoku region and to businesses which wish to adopt this technology after acquiring the necessary intellectual properties.

RESEARCH CONTENT

In order to meet the industrial needs, the further improvement in the soft magnetic properties (i.e. ultra-low core loss, higher saturation magnetic flux density) and material properties is required. Bulk or powder alloys have great potentials for its commercialization due to its advantages in processibilty or formibility. The project is dedicated to solve two technical issues as follows:

  • Improvement of magnetic performance of new magnetic materials
  • Commercialization of new magnetic materials

The four research groups are aimed to pursue the solutions to various issues in the commercialization and research, and their tasks is listed as follows:

  • (Group 1)Evaluation and Analysis of Magnetic Property
  • (Group 2)Theoretical Analysis and Computation Simulation: Establishment of guidelines for the creation of ideal-type nano structures.
  • (Group 3)Material Creation: Analysis and implementation of high precision material production processes.
  • (Group 4)Evaluation of Applicability: Theory construction and problem solving for commercialized technologies.

The four groups are dedicated to dig out the solutions to the two issues above mentioned through teamwork and collaboration in the following ways:

1. Improvement of magnetic performance of new magnetic materials

To improve material efficiency our project will elucidate essential mechanisms and advance collaboration across different research areas in the fields of magnetism and nano structures in order to develop innovative basic technologies.
On the basis of the work of the research groups on evaluation and analysis of magnetic properties, the mechanisms of magnetic loss expression and dynamic behavior observation of the magnetic domain structure and the magnetic fields is to be build up to contribute to the greatest possible minimization of magnetic core loss. Guidelines for the implementation of ideal-type nano-structures is to be established basing on these results of the analysis and simulation of organization and structure research group. Integration of the results of high precision direct observation and elucidation of the non-homogenous nature of amorphous structures and hetero structures, geometric and chemical high precision observation of nano structures, explanation of the relationship of such structures with soft magnetic properties, and simulation-based explanations of inhomogeneity and the self-organizing mechanisms of nano structures will contribute to the buildup of guidelines. Moreover, essential material design guidelines for
the implementation of loss reduction through controlling non-equilibrium type microcrystalline structure and high Bs based amorphous material will be done through the cooperation of these two groups.

2. Commercialization of new magnetic materials

In order to fulfill the commercialization of new materials and support the industrial thriving of the Tohoku region as a hub for these innovative basic technologies, these two groups (Materials creation and Evaluation of Applicability) contribute their efforts.

In detail, the material creation research group aims to investigate the dependency of the optimum heteromorphous structure with best magnetic properties on the cooling rates alloy composition, microstructure, and the geometric parameters(i.e. bulk, ribbon, powder), and to explore the better processes for the production of ideal magnetics. On the basis of its research, basic technologies for mass-production of new soft magnetic materials (i.e. sheets with ideal nano-crystalline structures, layers, powder consolidated bulk material, and high iron concentrated (high saturation magnetic flux density) nano crystalline material) is to be incubated. The cooperation with Ministry of Economy, Trade and Industry (METI) project aims at developing ultra-high efficiency nano-crystalline soft magnetic material.
Moreover, the applied performance evaluation research group engages in optimization of magnetic properties and the potentials for commercialization (sheets, powder, bulk etc.), conducts design simulations for the high efficiency motors and transformers, and engages in theory development on technology implementation and problem resolution. Meanwhile, this project cooperates with METI aiming at the practical application of magnetic products.

These two groups unite with relative companies to find out the industrial needs, the solutions to technical problems, and the exit to the solution-orientated collaborative researches in order to support the commercialization of the technologies within the industry. Moreover, the project is dedicated itself to innovation of basic technologies, the nourishing of human resources and technological exchange, as well as the multi-faceted collaboration between government, industry and academia in this field, and contributes to the flourishing of industries in the Tohoku region.

These two groups share with the participating and collaborating businesses market needs and technical problems. Building on this, they conduct solution-orientated collaborative research and support the commercialization of the technologies within the industry. Moreover, based on these innovative basic technologies this research advances the nourishing of human resources and technological exchange, as well as the multi-faceted collaboration between government, industry and academia in this field, and contributes to the flourishing of industries in the Tohoku region.

Significant reduction of energy loss and control of power transfer loss through the development of novel nano-crystalline soft magnetic materials.

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SHARED EQUIPMENT

  • High-intensity X-ray Diffractometer
  • High Resolution EPMA Device
  • Laser Diffraction Type Dry Process Particle Size Measurement Device
  • High Speed Temperature Raising Type Differential Scanning Calorimeter
  • High Grade Phrase Correspondence Response High Precision BH Analyzer
  • High Frequency Correspondence Type Impedance Analyzer
  • High Precision Density Measurement Electronic Balance
  • High Heat Response Type Differential Calorie Simultaneous Measurement Device