Effects of advanced magnetic materials in the DC and AC performance of inductors and transformers

Two main components of power conversion equipment (PCE) are inductors and transformers. PCE have a plethora of applications, but their size, weight, and cost reduction are challenging problems that need precise engineering attention to be resolved, and can be specific for each application. Hence, increased power density, magnetic performance, and thermal margin during PCE operation is of critical importance to the ever-present need to make these components smaller and more efficient. This can occur by incorporating new advanced magnetic (AdvMag) materials in their designs that will improve the PCE performance compared to the currently used magnetic materials consisting primarily of laminated electrical steels. Our current work is dedicated to a comprehensive comparison of these different new advanced magnetics materials and how they can be used to improve both DC (low frequency) and AC performance of inductors and transformers, leading to much more efficient PCE devices. We analyze the effects of these emerging materials both theoretically and by using full-wave simulations. We conclude that amorphous alloys and new light-weight nanocrystalline magnetic materials can serve as suitable substitutes of steel in laminated transformer designs. In addition, ferrites can also improve inductor and transformer operation as they possess excellent thermal properties, reduced weight, and low loss. Our results will be useful to power engineers working on new and improved PCE devices with smaller size, lighter weight, higher power density, and increased operational frequency.