Abstract: A bulk amorphous metal magnetic component has a plurality of laminations of ferromagnetic amorphous metal strips adhered together to form a generally three-dimensional part having the shape of a polyhedron. The component is formed by stamping, stacking and bonding. The bulk amorphous metal magnetic component may include an arcuate surface, and an implementation may include two arcuate surfaces that are disposed opposite each other. The magnetic component may be operable at frequencies ranging from between approximately 50 Hz and 20,000 Hz. When the component is excited at an excitation frequency “f” to a peak induction level Bmax, it may exhibit 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: A bulk amorphous metal inductive device includes a magnetic core having at least one low-loss bulk ferromagnetic amorphous metal magnetic component forming a magnetic circuit having an air therein. The component has a plurality of similarly shaped layers of amorphous metal strips bonded together to form a polyhedrally 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: Metallic glasses having high permeability, low coercivity, low ac core loss, low exciting power, and high thermal stability are disclosed. The metallic glasses are substantially completely glassy and consist essentially of about 71 to 79 atom percent iron, about 1 to 6 atom percent of at least one member selected from the group consisting of chromium, molybdenum, tungsten, vanadium, niobium, tantalum, titanum, zirconium and hafnium, about 12 to 24 atom percent boron, about 1 to 8 atom percent silicon, 0 to about 2 atom percent carbon, plus incidental impurities, the total of boron, silicon and carbon present ranging from about 18 to 28 atom percent. The alloy is heat treated at a temperature and for a time sufficient to achieve stress relief without inducing precipitation of discrete particles therein. Such a metallic glass alloy is especially suited for use in devices requiring high response to weak magnetic fields, such as ground fault interruptors and current/potential transformers.

Abstract: Metallic glasses having high permeability, low coercivity, low ac core loss, low exciting power, and high thermal stability are disclosed. The metallic glasses are substantially completely glassy and consist essentially of about 71 to 79 atom percent iron, about 1 to 6 atom percent of at least one member selected from the group consisting of chromium, molybdenum, tungsten, vanadium, niobium, tantalum, titanium, zirconium and hafnium, about 12 to 24 atom percent boron, about 1 to 8 atom percent silicon, 0 to about 2 atom percent carbon, plus incidental impurities, the total of boron, silicon and carbon present ranging from about 18 to 28 atom percent. The alloy is heated treated at a temperature and for a time sufficient to achieve stress relief without inducing precipitation of discrete particles therein. Such a metallic glass alloy is especially suited for use in devices requiring high response to weak magnetic fields, such as ground fault interruptors and current/potential transformers.