Abstract: A magnetic ribbon or sheet is coated with an electrical insulator prior to formation of a magnetic implement. Manufacture of the magnetic implement is accomplished in a single process without a need for co-winding magnetic and insulator ribbons. Thermal property differences between the magnetic material and the insulator operate during heat treatment to enhance magnetic property modification of the implement.

Abstract: A magnetic core has a toroidal configuration, formed by winding an iron-based amorphous metal ribbon. Thereafter the core is heat-treated to achieve a linear B-H characteristic. Advantageously, the linear B-H characteristic does not change with the level of magnetic fields applied and the frequency utilized. With such properties, the core is especially suited for use in a current transformer.

Abstract: A plurality of parts are brazed using an iron/chromium filler metal. The parts are preferably composed of stainless steel. The brazed assembly forms a heat exchanger characterized by good corrosion resistance and low rates of leaching of Ni, which are further improved by a post-brazing conditioning step in an oxygen-containing atmosphere at a temperature of about 150° to 600° C. The preferred brazing filler metal consists essentially of a composition having the formula FeaCrbCocNidMoeWfBgSih wherein the subscripts are in atom percent and total 100%, “b” is about 5 to 20, “c” ranges from 0 to about 30, “d” is 0 to about 20, “e” is 0 to about 5, “f” is 0 to about 5, “g” is about 8 to 15, “h” is about 8 to 15, the balance being incidental impurities of up to about 1 percent by weight of the total composition.

Abstract: A bulk amorphous metal inductive device comprises a magnetic core having at least one low-loss bulk ferromagnetic amorphous metal magnetic component forming a magnetic circuit having an air gap therein. The component comprises a plurality of similarly shaped layers of amorphous metal strips bonded together to form a polyhederally shaped part. The device has one or more electrical windings and is easily customized for specialized magnetic applications, e.g. for use as a transformer or inductor in power conditioning electronic circuitry employing switch-mode circuit topologies and switching frequencies ranging from 1 kHz to 200 kHz or more. The low core losses of the device, e.g. a loss of at most about 12 W/kg when excited at a frequency of 5 kHz to a peak induction level of 0.3 T, make it especially useful at frequencies of 1 kHz or more.

Abstract: A unitary amorphous metal magnetic component for an axial flux electric machine such as a motor or generator is formed from a spirally wound annular cylinder of ferromagnetic amorphous metal strips. The cylinder is adhesively bonded and provided with a plurality of slots formed in one of the annular faces of the cylinder and extending from the inner diameter to the outer diameter of the cylinder. The component is preferably employed in constructing a high efficiency, axial flux electric motor. When operated at an excitation frequency “f” to a peak induction level Bmax the unitary amorphous metal magnetic component 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, the core loss, excitation frequency and peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

Abstract: A high efficiency electric motor has a generally polyhedrally shaped bulk amorphous metal magnetic component in which a plurality of layers of amorphous metal strips are laminated together adhesively to form a generally three-dimensional part having the shape of a polyhedron. The bulk amorphous metal magnetic component may include an arcuate surface, and preferably includes two arcuate surfaces that are disposed opposite to each other. The magnetic component is operable at frequencies ranging from about 50 Hz to about 20,000 Hz. When the motor is operated at an excitation frequency “f” to a peak induction level Bmax, the component exhibits a core-loss less than about “L” wherein L is given by the formula L=0.005 f (Bmax)1.5+0.000012 f1.5 (Bmax)1.6, said core loss, said excitation frequency and said peak induction level being measured in watts per kilogram, hertz, and teslas, respectively.

Abstract: A plurality of parts are brazed using an iron/chromium brazing filler metal. The parts are preferably composed of stainless steel and the brazed assembly forms a heat exchanger characterized by good corrosion resistance and low rates of leaching of Ni into fluids passing therethrough. The heat exchanger is especially suited for use in processing items intended to be ingested by humans or animals. Leaching rates and corrosion resistance are further enhanced by a post-brazing conditioning step wherein the assembly is heated in an oxygen-containing atmosphere to a temperature ranging from about 150° to 600° C.

Abstract: A bulk amorphous metal inductive device comprises a magnetic core having plurality of low-loss bulk ferromagnetic amorphous metal magnetic components assembled in juxtaposed relationship to form at least one magnetic circuit and secured in position, e.g. by banding or potting. The device has one or more electrical windings and may be used as a transformer or inductor in an electronic circuit. Each component comprises a plurality of similarly shaped layers of amorphous metal strips bonded together to form a polyhedrally shaped part. The low core losses of the device, e.g. a loss of at most about 12 W/kg when excited at a frequency of 5 kHz to a peak induction level of 0.3 T, make it especially useful for application in power conditioning circuits operating in switched mode at frequencies of 1 kHz or more. Air gaps are optionally interposed between the mating faces of the constituent components of the device to enhance its energy storage capacity for inductor applications.

Abstract: A high efficiency electric motor has a generally polyhedrally shaped bulk amorphous metal magnetic component in which a plurality of layers of amorphous metal strips are laminated together to form a generally three-dimensional part having the shape of a polyhedron. The bulk amorphous metal magnetic component may include an arcuate surface, and preferably includes two arcuate surfaces that are disposed opposite to each other. The magnetic component is operable at frequencies ranging from about 50 Hz to about 20,000 Hz. When the motor is operated at an excitation frequency “f” to a peak induction level Bmax the component exhibits 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.

Abstract: The present invention relates to improved transformer cores formed from wound, annealed amorphous metal alloys, particularly multi-limbed transformer cores. Processes for the manufacture of the improved transformer cores, and transformers comprising the improved transformer cores are also described.

Abstract: An apparatus and method for casting metal strip includes a moving chill body that has a quench surface. A nozzle mechanism deposits a stream of molten metal on a quenching region of the quench surface to form the strip. The nozzle mechanism has an exit portion with a nozzle orifice. A depletion mechanism includes a plurality of independently controllable gas nozzles to supply a reducing gas to multiple zones of a depletion region located adjacent to and upstream from the quenching region. The gas flow profile can be controlled in each zone independently of controlling the gas flow in other zones. The reducing gas reacts exothermically to lower the density to provide a low density reducing atmosphere within the depletion and substantially prevent formation of gas pockets in the strip.