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Page 1: NAM Cat CombinedCh1

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Page 2: NAM Cat CombinedCh1

2475 LaPalma Ave., Anaheim, California 92801 TOLL FREE: 800-331-0278www. magmet.com PHONE: (+1) 714-828-4625Email: [email protected] Specifications02A_2001 FAX: (+1) 714-828-4279

� Page 1

Table of Contents

Introduction & SpecificationsIntroduction 2Materials for “C”, “E” and toroids 4Material selection tables 9“C” Core tolerances for single phase 11“E” Core tolerances for three phase 12Uncased toroid tolerances 13“C” Core banding instructions 14Magnetic unit conversions 15

Silicon Steel (SILECTRON®)Essential raw material properties 16One to twelve thousandths of an inch parts 19Graphs for silicon steel 31

50:50 Nickel-Iron Alloy (Deltamax)Essential raw material properties 40One and two thousandths of an inch parts 43Graphs for 50:50 nickel-iron alloy 45

79:15:5 Ni-Fe-Mo (Supermalloy)Essential raw material properties 47One and two thousandths of an inch parts 50Graphs for 79:15:5 Ni-Fe-Mo alloy 52

49:49:2 Co-Fe-V (Supermendur)Essential raw material properties 54Four thousandths of an inch parts 57Graphs for 49:49:2 Co-Fe-V alloy 58

Amorphous Alloy (NAMGLASS® 1)Essential raw material properties 60One thousandth of an inch parts 62Graphs for amorphous iron alloy 63

Nanocrystalline Alloy (NAMGLASS® 4)Essential raw material properties 64One thousandth of an inch parts 67Graphs for nanocrystalline alloy 68

Page 3: NAM Cat CombinedCh1

Magnetic Metals Corp has over 30 yearsexperience manufacturing soft magnetic strip coresusing grain oriented silicon steel, nickel, cobalt andamorphous alloys. We strive to produce the highestquality tape-wound cores in the industry, thatmechanically and electrically meet your require-ments and our product specifications. We excel incustom magnetic applications. However a “stan-dard” core exceeds industry standards in manyareas:

• Wide selection of raw materials suitable for abroad range of applications• Precision material slitting• Superior high dielectric nickel, cobalt and amor-phous metal coatings• State-of-the-art heat treating and stress reliefannealing• Bonded with high temperature, heat stable, epoxyresins. Cores are typically heat stable to 350°F(175°C) and up to 425°F (218°C) with specialprocessing• Precision cutting• The mating surfaces of our cores are polished to aminimal air gap of typically 0.75 thousandths of aninch• Mating surfaces are beveled to reduce delamina-tion• Chemical treatment of polished surfaces to maxi-mize corrosion resistance• Mechanical tolerances are held to EIA standardRS-217-A for “C” cores. All other configurationsare to specified tolerances• Each core is marked with a part number and datecode for traceability• Robust packing is used to prevent damage forshipment around the world

There is much that can be done to customize a coreto meet your specific needs. Some of the processesthat can improve a core’s performance are detailedin the following bullets:

• Double impregnation eliminates loose laminationsthat may vibrate when the core is excited. Thiscombined with diamond lapping further reduces gapvibration and acoustical noise• Diamond lapping also reduces gap volt-amps(VA) for lowest possible current. Both low noiseand gap VA can be assured by diamond lapping toan approximate 0.15 thousandths of an inch surfaceflatness• A special thermal cycle can be performed tominimize gap shifting for the ultimate in low noiseperformance or to compensate for operating temper-atures up to a maximum of 425°F (218°C). This isa desirable option when normal gap shift duringthermal cycling cannot be tolerated• Epoxy coating can be substituted for taping whenit is necessary to wind directly on the core or maxi-mum protection against high voltage breakdown isrequired• Toroids can be cut on the center-line or gapped tomeet an inductance or a customer required gapspacing• Multiple gaps can be cut in a core to reducefringe flux and gap power losses• Rounded or beveled edges can be made to reducecorona or delamination• Nonstandard or unusual shapes and sizes can beengineered for novel applications• Special mechanical and electrical testing can beperformed to insure conformance to your designrequirements. For example, we can perform pulsetesting for pulse widths down to 100 nanosecondsand pulse energies up to 4 joules with completewaveform analysis capability

Page 2 Introduction & Specifications

2475 LaPalma Ave., Anaheim, California 92801 TOLL FREE: 800-331-0278www. magmet.com PHONE: (+1) 714-828-4625Email: [email protected] Specifications02A_2001 FAX: (+1) 714-828-4279

Page 4: NAM Cat CombinedCh1

Introduction & Specifications Page 3

Find out more about our products from these GroupArnold companies:

Magnetic Metals Corporation2475 LaPalma AvenueAnaheim, California 92801

Toll Free: 800-331-0278Phone: (+1) 714-828-4625

FAX: (+1) 714-828-4279

Magnetic Metals Corporation1900 Hayes AvenueCamden, New Jersey 08105

Phone: (+1) 856-964-7842FAX: (+1) 856-757-9047

Visit us on-line at www.magmet.com.

The pages in this section include a table of contentsfor the complete catalogue and the product specifi-cations. The specifications section covers materialspecifications for cut cores and toroids, and me-chanical tolerances for “C”, “E” and uncasedtoroids. This terminology is mostly descriptive ofthe shape of individual cut core sections, whenlooking down on the exposed lamination edges. Atoroid refers to a circular shaped core, includingcuts if present. The figures show a typical “E”core, “C” core and Toroid.

2475 LaPalma Ave., Anaheim, California 92801 TOLL FREE: 800-331-0278www. magmet.com PHONE: (+1) 714-828-4625Email: [email protected] Specifications02A_2001 FAX: (+1) 714-828-4279

Page 5: NAM Cat CombinedCh1

Material Specifications for Cut “C” Cores

OTHER MATERIALS AVAILABLE IN “C” CORE (SINGLE PHASE) CONFIGURATIONS. CONTACT CUSTOMER SERVICE FOR DETAILS.

1. 3% grain oriented Silicon Steel. SILECTRON® is a registeredtrademark of Allegheny Ludlum Steel Corporation2,3,4. Deltamax is the discontinued product name of Allegh-eny Ludlum Steel Corporation. Supermalloy is the discontin-ued product name of Western Electric Company.Supermendur is the discontinued product name of CarpenterTechnology5. Iron based amorphous alloy. NAMGLASS® is a registeredtrademark of Magnetic Metals Corp.6. Nanocrystalline alloy. NAMGLASS® is a registered trademarkof Magnetic Metals Corp.

7. kG is kilogauss. Reported power loss (Watts/lb) measuredat the indicated flux (B), frequency (Hz) with sine waveexcitation. Watts = Watts/lb × pounds8,9. The formulas used to calculate Gap VA:K × B2 × (frequency) × SF2 × A

g, A

g is the gross core area,

K = 4.1 × 10-4 for a 0.001” gap, 8.2x10-4 for a 0.002” gap. Use0.001” gap for cores at or under 25 pounds. Use 0.002” gapfor cores over 25 pounds. Flux is measured in kilogauss, A

g in

square inches, frequency in Hertz, SF is dimensionless. TotalVA = Matl VA + Gap VA, Matl VA = Matl VA/lb × pounds,Gap VA = Gap VA/in2 × A

g

Page 4 Introduction & Specifications

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2475 LaPalma Ave., Anaheim, California 92801 TOLL FREE: 800-331-0278www. magmet.com PHONE: (+1) 714-828-4625Email: [email protected] Specifications02A_2001 FAX: (+1) 714-828-4279

Page 6: NAM Cat CombinedCh1

Introduction & Specifications Page 5

Material Specifications for Cut “E” Cores

OTHER MATERIALS AVAILABLE IN “E” CORE (THREE PHASE) CONFIGURATIONS. CONTACT CUSTOMER SERVICE FOR DETAILS.

4,5. The formulas used to calculate Gap VA:K × B2 × (frequency) × SF2 × A

g, A

g is the gross core area,

K = 6.15 × 10-4 for a 0.0015” gap, 12.3x10-4 for a 0.003” gap.Use 0.0015” gap for cores at or under 25 pounds. Use 0.003”gap for cores over 25 pounds. Flux is measured in kilogauss,A

g in square inches, frequency in Hertz, SF is dimensionless.

Total VA = Matl VA + Gap VA, Matl VA = Matl VA/lb ×pounds, Gap VA = Gap VA/in2 × A

g

1. 3% grain oriented Silicon Steel. SILECTRON® is a registeredtrademark of Allegheny Ludlum Steel Corporation2, Supermendur is the discontinued product name of Carpen-ter Technology3. kG is kilogauss. Reported power loss (Watts/lb) measuredat the indicated flux (B), frequency (Hz) with sine waveexcitation. Watts = Watts/lb × pounds

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2475 LaPalma Ave., Anaheim, California 92801 TOLL FREE: 800-331-0278www. magmet.com PHONE: (+1) 714-828-4625Email: [email protected] Specifications02A_2001 FAX: (+1) 714-828-4279

Page 7: NAM Cat CombinedCh1

Material Specifications for Uncased Toroids

OTHER MATERIALS AVAILABLE IN UNCASED TOROIDAL CONFIGURATIONS. CONTACT CUSTOMER SERVICE FOR DETAILS.

7. kG is kilogauss. Reported power loss (Watts/lb) measuredat the indicated flux (B), frequency (Hz) with sine waveexcitation. Watts = Watts/lb × pounds8,9. The formulas used to calculate Gap VA:K × B2 × (frequency) × SF2 × A

g, A

g is the gross core area,

K = 4.1 × 10-4 for a 0.001” gap, 8.2x10-4 for a 0.002” gap. Use0.001” gap for cores at or under 25 pounds. Use 0.002” gapfor cores over 25 pounds. Flux is measured in kilogauss, A

g in

square inches, frequency in Hertz, SF is dimensionless. TotalVA = Matl VA + Gap VA, Matl VA = Matl VA/lb × pounds,Gap VA = Gap VA/in2 × A

g

1. 3% grain oriented Silicon Steel. SILECTRON® is a registeredtrademark of Allegheny Ludlum Steel Corporation2,3,4. Deltamax is the discontinued product name of Allegh-eny Ludlum Steel Corporation. Supermalloy is the discontin-ued product name of Western Electric Company.Supermendur is the discontinued product name of CarpenterTechnology5. Iron based amorphous alloy. NAMGLASS® is a registeredtrademark of Magnetic Metals Corp.6. Nanocrystalline alloy. NAMGLASS® is a registered trademarkof Magnetic Metals Corp.

Page 6 Introduction & Specifications

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2475 LaPalma Ave., Anaheim, California 92801 TOLL FREE: 800-331-0278www. magmet.com PHONE: (+1) 714-828-4625Email: [email protected] Specifications02A_2001 FAX: (+1) 714-828-4279

Page 8: NAM Cat CombinedCh1

Introduction & Specifications Page 7

Material Specifications for Cased Toroids ... continued on next page

OTHER MATERIALS AVAILABLE IN CASED TOROIDAL CONFIGURATIONS. CONTACT CUSTOMER SERVICE FOR DETAILS.1. 3% grain oriented Silicon Steel. SILECTRON® is a registeredtrademark of Allegheny Ludlum Steel Corporation2,3,4,5,6. Deltamax is the discontinued product name ofAllegheny Ludlum Steel Corporation. Supermalloy is thediscontinued product name of Western Electric Company.Permalloy is the discontinued product name of WesternElectric Company, Bell Telephone Laboratories, StandardTelephone. Supermendur is the discontinued product name ofCarpenter Technology7. B

m is the maximum flux of the material in kilogauss

measured at the given drive level, Hm, in oersteds

8. (Bm - B

r) is the difference between the maximum flux, B

m,

and the remanence, Br ( residual induction). (B

m – B

r) is a

measure of “Squareness” of the hysteresis loop in kilogauss9. CCFR settings refer to the drive level (H

m) and flux density

for a Constant Current Flux Reset test set with sine currentexcitation. Net area is required for all measurements. InCCFR terms: H

1 is a measure of coercive force (slightly

larger). Twice the swing in flux density, B, divided by delta His the incremental permeability for a given drive level, H

m.

Hm, H

1 and delta H are in oersteds

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2475 LaPalma Ave., Anaheim, California 92801 TOLL FREE: 800-331-0278www. magmet.com PHONE: (+1) 714-828-4625Email: [email protected] Specifications02A_2001 FAX: (+1) 714-828-4279

Page 9: NAM Cat CombinedCh1

Material Specifications for Cased Toroids ... continued from previous page

HOW TO SPECIFY CASED TOROIDS

EXAMPLE:3 T05320 51 02 (See examples page 9)

CASE & DAMPING CORE SIZE

1 = Aluminum, anodized, silicon grease THICKNESS & ANNEAL

8 = Aluminum, epoxy coat, silicon rubber 05 = 0.0005” not SILECTRON®

3 = Machined nylon, silicon grease 01 = 0.001”4 = Machined nyon, silicon oil filled 02 = 0.002”7 = Molded glass nylon, MATERIAL TYPE 04 = 0.004”

silicon grease 40 = SILECTRON® 05 = 0.004” “Z” matl. SILECTRON

30 = Supermendur (cobalt) 07 = 0.007”UNCASED TOROIDS 51 = Deltamax (50% nickel) 08 = 0.007” “Z” material

STACKING FACTORS 80 = Supermalloy (79% nickel) 09 = 0.009” “Z” material0.0005” = 0.50 79 = 4-79 Permalloy 12 = 0.012” not 21 or 24 matl.0.001” = 0.75 81 = Square Permalloy 13 = 0.011” “Z” material0.002” = 0.85 21 = NAMGLASS® 1 (Iron Amorphous) 11 = 0.001” Square 21, 24 matl.0.004” = 0.90 24 = NAMGLASS 4 (Nanocrystalline) 12 = 0.001” Round 21, 24 matl.

1. 3% grain oriented Silicon Steel. SILECTRON® is a registeredtrademark of Allegheny Ludlum Steel Corporation2. Supermendur is the discontinued product name of Carpen-ter Technology

3. B, Frequency is the test point for the given Max Core Lossand Max Volt-Amps

Page 8 Introduction & Specifications

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Page 10: NAM Cat CombinedCh1

Introduction & Specifications Page 9

Material Selection Tables ... continued on next page

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Page 11: NAM Cat CombinedCh1

Material Selection Tables ... continued from previous page

1. “mil” is the English equivalent for thousandth of an inch2. SS is the abreviation for 3% grain oriented silicon steel3. NAMGLASS® is a registered trademark of Magnetic Metals4. 80:20 Ni:Fe refers to 79:15:5 Ni-Fe-Mo and similar alloys5. AC choke, DC filter choke sometimes called inductors6. Sq 80:20 Ni:Fe, Sq Ferrite refer to square loop annealing7. Cobalt Amorphous - Low flux , very low loss square alloy

Frequency is only one of several important parameters indefining an application. Factors such as size, weight andthermal environment are also important. Therefore thematerial selections indicated in the table should be consideredas starting points only, subject to change depending on thespecifics of the application. Contact customer service for helpin refining these suggestions for your requirements

1. ms is the abreviation for milliseconds. 103 ms = 1 second2. µs is the abreviation for microseconds. 106 µs = 1 second3. ns is the abreviation for nanoseconds. 109 ns = 1 second4. “mil” is the English equivalent for thousandths of an inch5. SS is the abreviation for 3% grain oriented silicon steel6. “High B” is the abreviation for high flux material7. NAMGLASS® is a registered trademark of Magnetic Metals

Pulse width is only one of several important parametersdefining an application. Factors such as size, weight andthermal environment are also important. Therefore thematerial selections indicated in the table should be consideredas starting points only, subject to change depending on thespecifics of the application. Contact customer service for helpin refining these suggestions for your requirements

Page 10 Introduction & Specifications

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Page 12: NAM Cat CombinedCh1

Introduction & Specifications Page 11

Tolerances for C-Cores (Single Phase)AS DEFINED BY EIA STANDARD RS-217-A FOR WOUND CORES

C-CoreStacking Factors:0.0005” = .650.001” = .831

0.002” = .890.004” = .900.007” = .920.009” = .950.011” = .950.012” = .95

1. 0.75 used forG1, W2 options

A (NOMINAL) = F + 2XGB (NOMINAL) = G + 2XE

K = G/2 IF G < 3.750”K = 1.688” IF G >= 3.750”

NOTE: A & B dimensions are held to maximum only. Negative tolerance for A & B is leftopen and is controlled by F, G & E dimensions. F & G dimensions are held to minimumonly. Positive tolerance for F & G is left open and controlled by the A, B & E dimensions.

HOW TO SPECIFY CUT C-CORES

EXAMPLE:C M N8S - 10000 (See examples page 9)

Magnetic Metals PART CORE SIZE (5 DIGITS OR LESS)

MATERIAL THICKNESS MATERIAL TYPE

P = 0.0005” BZ = 0.009” (High B) Blank = SILECTRON®

M = 0.001” A = 0.012” C = Supermendur (Cobalt)L = 0.002” AZ = 0.011” (High B) N5D = Deltamax (50% Nickel)H = 0.004” N8S = Supermalloy (79% Nickel)Z = 0.004” (High B) G1 = NAMGLASS® 1 (Iron Amorphous)J = 0.007” W2 = NAMGLASS 4 (Nanocrystalline)JZ = 0.007” (High B )

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Page 13: NAM Cat CombinedCh1

Tolerances for E-Cores (Three Phase)

NOTE: A & B dimensions are held to maximum only. Negative tolerance for A & B isleft open and is controlled by F, G & 2E dimensions. F & G dimensions are held tominimum only. Positive tolerance for F & G is left open and controlled by the A, B &2E dimensions

A (NOMINAL) = 2F +3X2EB (NOMINAL) = G + 2X2E

K = G/2 FOR ALL

E-CoreStacking Factors:0.0005” = .650.001” = .831

0.002” = .890.004” = .900.007” = .920.009” = .950.011” = .950.012” = .95

1. 0.75 used forG1, W2 options

HOW TO SPECIFY CUT E-CORES

EXAMPLE:C T H - 11680 (See examples page 9)

Magnetic Metlas Part THREE PHASE CORE SIZE (5 DIGITS OR LESS)

MATERIAL THICKNESS MATERIAL TYPE

P = 0.0005” BZ = 0.009” (High B) Blank = SILECTRON®

M = 0.001” A = 0.012” C = Supermendur (Cobalt)L = 0.002” AZ = 0.011” (High B) N5D = Deltamax (50% Nickel)H = 0.004” N8S = Supermalloy (79% Nickel)Z = 0.004” (High B) G1 = Namglass® 1 (Iron Amorphous)J = 0.007” W2 = Namglass 4 (Nanocrystalline)JZ = 0.007” (High B )

Page 12 Introduction & Specifications

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Page 14: NAM Cat CombinedCh1

Introduction & Specifications Page 13

Tolerances for Uncased Toroids

NOTE: For unimpregnated cores, measurements shall be made with core shaped intomost favorable position (minimum eccentricity), because these cores are often flexible

NOTE: For coated cores, add 0.040” to the maximum “OD” and “D” dimensions.Subtract 0.040” from the minimum “ID” dimension. “E” dimension tolerance appliesbefore coating

OD(NOMINAL) = ID + 2XE

Uncased ToroidsStacking Factors:0.0005” = .650.001” = .831

0.002” = .890.004” = .900.007” = .920.009” = .950.011” = .950.012” = .95

1. 0.75 used forG1, W2 options

HOW TO SPECIFY TOROIDAL CORES

EXAMPLE:C R L N5D - 10020 (See examples page 9)

Magnetic Metals PART

TOROID CORE SIZE (5 DIGITS OR LESS)

MATERIAL THICKNESS MATERIAL TYPE

P = 0.0005” BZ = 0.009” (High B) Blank = SILECTRON®

M = 0.001” A = 0.012” C = Supermendur (Cobalt)L = 0.002” AZ = 0.011” (High B) N5D = Deltamax (50% Nickel)H = 0.004” N8S = Supermalloy (79% Nickel)Z = 0.004” (High B) G1 = NAMGLASS® 1 (Iron Amorphous)J = 0.007” W2 = NAMGLASS 4 (Nanocrystalline)JZ = 0.007” (High B )

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Page 15: NAM Cat CombinedCh1

Banding Instructions for “C” Cores

TYPICAL BANDING EXAMPLES

SIMPLE CONFIGURATION

Single “C” Core, Single CoilDOUBLE COIL GEOMETRY

Single “C” Core, Double CoilSHELL CONFIGURATION

Double “C” Core, Single Coil

Step 1: Place bobbin coil(s) over longer leg(s) of coreStep 2: Fit & align core halves, i.e., mate cap as shownStep 3: Select band(s), wrap around circumference

Step 4: Thread band(s) through sealing sleeve(s)Step 5: Tension band(s) per table recommendationsStep 6: Crimp seal(s) &/or apply sealant/solder as reqd.

1. Westinghouse Electric Corporation, Specialty Transformer Division 1968 Catalogue

Page 14 Introduction & Specifications

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2475 LaPalma Ave., Anaheim, California 92801 TOLL FREE: 800-331-0278www. magmet.com PHONE: (+1) 714-828-4625Email: [email protected] Specifications02A_2001 FAX: (+1) 714-828-4279

Page 16: NAM Cat CombinedCh1

Introduction & Specifications Page 15

Magnetic Unit Conversions

Instructions for use: To convert from units in a column on theleft to units in a column on the right, multiply by the numbersin the column in-between. For example, if it is desired toconvert tesla to gauss, multiply the flux density or magneticinduction by 104 or 10000, the number between tesla on theleft and gauss on the right, to get flux density in gauss. Thus1.5 tesla is 15,000 gauss or 15 kilogauss. Conversely, theconversion from gauss to tesla is done by using 10-4, thenumber between gauss on the left and tesla on the right, as theconversion factor.

A second example follows. If it is necessary to convert fromjoules to ergs, then look down the MKS unit column for joule.Select the number to the right of joule, which is 107. Multiply

107 by the joule value that needs to be converted. Thus if 4joules needs to be expressed in ergs, then multiply 4 by 107 toget 4 × 107 ergs.

Magnetic Metals Corp uses the CGS system formagnetic units and the English system for dimensional units inthe catalogue. Consult customer service about unit conversionissues not defined in this table.

1. Conversion factors compiled from various texts includ-ing “Magnetism and Metallurgy of Soft Magnetic Materi-als”, Chih-Wen Chen, Dover, 1977; “The MagneticCircuit”, V. Karapetoff, McGraw-Hill, 1911

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2475 LaPalma Ave., Anaheim, California 92801 TOLL FREE: 800-331-0278www. magmet.com PHONE: (+1) 714-828-4625Email: [email protected] Specifications02A_2001 FAX: (+1) 714-828-4279