System and method for making a structured magnetic material with integrated particle insulation

1. A system that makes a material having domains with insulated boundaries, the system comprising:

a droplet spray subsystem configured to create molten alloy droplets and direct the molten alloy droplets to a surface;

a gas subsystem configured to introduce one or more reactive gases to an area proximate in-flight droplets;

wherein the one or more reactive gases creates an insulation layer on the droplets in-flight such that the droplets form a material having a plurality of substantially void free adhered domains, substantially all surfaces of the domains of the plurality of substantially void free adhered domains separated by insulated boundaries formed from the insulation layer; and

a spray subsystem coupled to the gas subsystem and including at least one port configured to introduce an insulation promoting agent proximate the in-flight droplets which coats the molten alloy droplets and stimulates a chemical reaction between the insulation promoting agent and the molten alloy droplets to facilitate formation of the insulation layer on the droplets in-flight, the spray subsystem further including a charging plate configured to control trajectories of the molten alloy droplets to the surface.

2. The system of claim 1 in which the droplet spray subsystem includes a crucible configured to create the molten metal alloy and direct the molten alloy droplets towards the surface.

3. The system of claim 1 in which the droplet spray subsystem includes a wire arc droplet deposition subsystem configured to create the molten metal alloy droplets and direct the molten alloy droplets towards the surface.

4. The system of claim 1 in which the droplet subsystem includes one or more of: a plasma spray droplet deposition subsystem, a detonation spray droplet deposition subsystem, a flame spray droplet deposition subsystem, a high velocity oxygen fuel spray (HVOF) droplet deposition subsystem, a warm spray droplet deposition subsystem, a cold spray droplet deposition subsystem, and a wire arc droplet deposition subsystem each configured to form the molten metal alloy droplets and direct the molten alloy droplets towards the surface.

5. The system of claim 1 in which the gas subsystem includes a spray chamber having one or more ports configured to introduce the one or more reactive gases proximate the in-flight droplets.

6. The system of claim 1 in which the gas subsystem includes a nozzle configured to introduce the one or more reactive gases to the in-flight droplets.

7. The system of claim 1 in which the surface is movable.

8. The system of claim 7 further including a mold on the surface configured to receive the droplets and form the material having domains with insulated boundaries in a shape of the mold.

9. The system of claim 1 in which the droplet spray subsystem includes a uniform droplet spray subsystem configured to generate the droplets having a uniform diameter.

10. The system of claim 1 in which the one or more gases include reactive atmosphere.

11. The system of claim 7 further including a stage configured to move the surface location in one or more predetermined directions.

12. The system of claim 8 further including a stage configured to move the mold in one or more predetermined directions.

13. A system that makes a material having domains with insulated boundaries, the system comprising:

a spray chamber;

a droplet spray subsystem coupled to the spray chamber configured to create molten alloy droplets and direct the molten alloy droplets to a predetermined location in the spray chamber;

a gas subsystem configured to introduce one or more reactive gases into the spray chamber proximate in-flight droplets;

wherein the one or more reactive gases creates an insulation layer on the droplets in-flight such that the droplets form a material having a plurality of substantially void free adhered domains, substantially all surfaces of the domains of the plurality of substantially void free adhered domains separated by insulated boundaries formed from the insulation layer; and

a spray subsystem coupled to the gas subsystem and including at least one port coupled to the spray chamber configured to introduce an insulation promoting agent proximate the in-flight droplets which coats the molten alloy droplets and stimulates a chemical reaction between the insulation promoting agent and the molten alloy droplets to facilitate formation of the insulation layer on the droplets in-flight, the spray subsystem further including a charging plate configured to control trajectories of the molten alloy droplets to the predetermined location in the spray chamber.