ULTRA-LOW COBALT IRON-COBALT MAGNETIC ALLOYS
A magnetic iron alloy and process of making the same. The alloy includes iron, approximately 2 wt. % to approximately 10 wt. % cobalt, approximately 0.05 wt. % to approximately 5 wt. % manganese, and approximately 0.05 wt. % to approximately 5 wt. % silicon. The alloy may also include up to approximately 3 wt. % chromium, up to approximately 2 wt. % vanadium, up to approximately 1 wt. % nickel, up to approximately 0.05 wt. % niobium, and up to approximately 0.02 wt. % carbon.
1 . A magnetic iron alloy comprising:
Iron (Fe);
approximately 2 wt. % to approximately 10 wt. % cobalt (Co);
approximately 0.05 wt. % to approximately 5 wt. % manganese (Mn); and
approximately 0.05 wt. % to approximately 5 wt. % silicon (Si).
2 . The magnetic iron alloy of claim 1 , further comprising one or more of:
chromium up to approximately 3 wt. %;
vanadium up to approximately 2 wt. %;
nickel up to approximately 1 wt. %;
niobium up to approximately 0.05 wt. %; and
carbon up to approximately 0.02 wt. %.
3 . The magnetic iron alloy of claim 1 , wherein the alloy has an electrical resistivity (ρ) of at least approximately 40 μΩcm.
4 . The magnetic iron alloy of claim 1 , wherein the alloy has a saturation induction (B s ) of at least approximately 20 kG.
5 . The magnetic iron alloy of claim 1 , wherein the alloy has a coercivity (H c ) of less than approximately 2 Oe.
6 . The magnetic iron alloy of claim 1 , wherein the alloy has an ρ of at least approximately 40 μΩcm, a B s of at least approximately 20 kG, and a H c of less than approximately 2 Oe
7 . The magnetic iron alloy of claim 1 , wherein the alloy comprises primarily a single alpha (α) phase.
8 . The magnetic iron alloy of claim 7 , wherein the alloy comprises at least approximately 95% of the alpha phase.
9 . The magnetic iron alloy of claim 7 , wherein the alloy comprises at least approximately 99% of the alpha phase.
10 . The magnetic iron alloy of claim 1 , wherein the alloy comprises approximately 2 wt. % to approximately 8 wt. % Co.
11 . The magnetic iron alloy of claim 1 , wherein the alloy comprises approximately 2 wt. % to approximately 5 wt. % Co.
12 . The magnetic iron alloy of claim 1 , wherein the alloy comprises approximately 10 wt. % Co, approximately 2.7 wt. % Mn, and approximately 1.3 wt. % Si.
13 . The magnetic iron alloy of claim 1 , wherein the alloy comprises approximately 8 wt. % Co, approximately 2.2 wt. % Mn, and approximately 1.3 wt. % Si.
14 . The magnetic iron alloy of claim 1 , wherein the alloy comprises approximately 5 wt. % Co, approximately 2.2 wt. % Mn, and approximately 1.3 wt. % Si.
15 . The magnetic iron alloy of claim 1 , wherein the alloy comprises approximately 5 wt. % Co, approximately 1.0 wt. % Mn, and approximately 2.3 wt. % Si.
16 . A magnetic iron alloy comprising:
iron;
approximately 2 wt. % to approximately 10 wt. % cobalt;
approximately 0.05 wt. % to approximately 5 wt. % manganese; and
approximately 0.05 wt. % to approximately 5 wt. % silicon,
wherein the alloy has a ρ of at least approximately 40 μΩcm, a B s of at least approximately 20 kG, and a H c of less than approximately 2 Oe.
17 . The magnetic iron alloy of claim 16 , further comprising one or more of chromium up to approximately 3 wt. %;
vanadium up to approximately 2 wt. %;
nickel up to approximately 1 wt. %;
niobium up to approximately 0.05 wt. %; and
carbon up to approximately 0.02 wt. %.
18 . The magnetic iron alloy of claim 16 , wherein the alloy comprises at least approximately 95% of the alpha phase.
19 . The magnetic iron alloy of claim 16 , wherein the alloy comprises at least approximately 99% of the alpha phase.
20 . The magnetic iron alloy of claim 16 , wherein the alloy is selected from the group consisting of:
an alloy including approximately 10 wt. % Co, approximately 2.7 wt. % Mn, and approximately 1.3 wt. % Si;
an alloy including approximately 8 wt. % Co, approximately 2.2 wt. % Mn, and approximately 1.3 wt. % Si;
an alloy including approximately 5 wt. % Co, approximately 2.2 wt. % Mn, and approximately 1.3 wt. % Si; and
an alloy including approximately 5 wt. % Co, approximately 1.0 wt. % Mn, and approximately 2.3 wt. % Si.