In this DARPA STTR Phase I program, Metamagnetics Inc., in collaboration with Northeastern University, proposes to address the challenges associated with performance of transformer and inductor materials operating at high power and frequencies equal to or greater than 50 kHz by developing ferromagnetic ferrimagnetic composites with high saturation magnetization, high permeabilities, and ultralow losses. These innovative composites, referred to here as m-ferro + n-ferri composites, consist of a dense collection of aligned ferromagnetic metallic microfibers coated with insulating and magnetically permeable ferrite particles forming a high-density composite core. Processing will be carried out via slip casting as desired engineered shapes. High density finished products or subcomponents will be assembled into finished products by additive manufacturing practices. The goal is to demonstrate feasibility of new materials and manufacturing methods for soft magnet materials having improved thermal performance, lower losses at high switching frequencies, and higher power ratings in smaller form factors for use as inductors and transformers in power electronic applications.
