Amorphous Core Transformers

Amorphous cores are made from similar metallic-glass alloys, but with randomly arranged, noncrystalline structures. These cores offer high resistivity and low loss at high frequencies.

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Amorphous cores get their name from their random atomic structure, which differs from the ordered, crystalline structure typical of metal or nanocrystalline cores. The unstructured arrangement of atoms increases resistivity compared to crystalline alloys, improving frequency response and efficiency, and allowing for extremely low loss at higher frequencies.  Advantages of using amorphous cores: The benefits of amorphous cores are rooted in their random atomic structure, which lacks the sort of structural anomalies that can interfere with magnetic performance. Key advantages of amorphous materials include: High permeability High magnetic density Reduced distribution and core losses Wide range of frequency properties Low coercivity forces Low no-load loss Low temperature rise Affordably priced Excellent resistance to corrosion High harmonic wave tolerances
  • Reduced no-load losses. A tape wound core made from amorphous material can achieve no-load loss reductions of up to 30% compared to silicon steel. These performance enhancements come from the random grain structure and high permeability, which serve to reduce both hysteresis loss and eddy current loss.
  • Improved overload capacity. As a result of reduced losses, amorphous tape wound cores generate less heat than conventional materials. Not only does this decrease wear on insulation, but it also improves overload capacity. 
  • Heightened efficiency. Another benefit of reduced no-load loss is a more favorable efficiency distribution. The significant efficiency improvements of amorphous cores help users reduce energy loss and decrease operating costs over the long term.
  • Limited environmental impact. Along with increased efficiency comes reductions in CO2 and SO2 emissions. As a result, amorphous cores are often more environmentally friendly than conventional alternatives. 
Amorphous core industry applications:  Amorphous magnetic cores allow OEMs to decrease component size and reduce weight while still improving electrical performance. These benefits make amorphous cores an excellent choice for high-frequency applications such as inverters, adjustable speed drives, and both switched-mode and uninterruptible power supplies (SMPS and UPS). Additional applications include: AC and DC transformers Inductors Common mode and differential mode chokes Magnetic amplifiers Craftsmanship Amorphous alloys are formed by adding a certain amount of glass forming agent to the molten metal, and rapidly quenching and casting using a narrow ceramic nozzle under high temperature melting conditions. Amorphous alloys have the similar characteristics of glass structure, which not only make them have excellent mechanical properties, physical properties and chemical properties, but more importantly, the new technology of producing amorphous alloys using this rapid quenching method is less than the cold-rolled silicon steel sheet process. 6 to 8 processes can save energy consumption by 60% to 80%, which is an energy-saving, time-saving and efficient metallurgical method. Moreover, the amorphous alloy has low coercivity and high magnetic permeability, and its core loss is significantly lower than that of oriented cold-rolled silicon steel sheet, and its no-load loss can be reduced by about 75%. Therefore, the use of amorphous alloys instead of silicon steel sheets to manufacture transformer cores is one of the main means to save energy and reduce consumption in today’s power grid equipment.

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