Somaloy will be the topic of this article. We will discuss its types and characteristics.
Definition of Somaloy
Somaloy® is Höganäs’ trademark for soft magnetic composite powders with unique 3D flux properties. The Somaloy materials are developed for component manufacturing of electromagnetic applications, providing high performance and low losses.
Kinds of Somaloy
Somaloy 1P
1P means that you press the part and process it singly. The 1P processing is designed to improve the mechanical strength of your electromagnetic component. 1P is still heat-treated. This processing method provides Somaloy 1P with a maximum permeability of about 550. The performance of Somaloy 1P is uniformly compared; the 1P soft magnetic composite series is considered the most economical baseline option.
Somaloy 3P
The 3P process involves more processing steps. In the 3P process, Somaloy powder is first pressed, and then a magnetic oxide coating is applied to the particles. These two extra steps enhance magnetic permeability (up to 700 or even higher) and provide excellent mechanical strength. Somaloy 3P focuses on high strength and high magnetic permeability, suitable for applications with specific mechanical performance requirements.
Somaloy 5P
Somaloy 5P implies a more complex process compared to 1P and 3P. Somaloy 5P is prepared in an environment slightly above the nitrogen temperature. The more complex steps occur at annealing temperatures for the compacted iron powder. The advantage of Somaloy 5P is that it has the lowest losses, meeting the customer’s requirement for low-loss materials. However, due to its complex processing, 5P is the most expensive option.
Comparison of Characteristics of Somaloy 700 1P, Somaloy 700 3P, and Somaloy 700 5P
| Property | Somaloy 700 1P | Somaloy 700 3P | Somaloy 700 5P |
|---|---|---|---|
| Processing | Basic compaction, single-stage heat treatment (low temperature). | Compaction, magnetic oxide coating, two-stage heat treatment in air + steam at 530 °C. | Compaction, high-temperature annealing in nitrogen at 650 °C. |
| Permeability | Up to 500. | Up to 700. | Up to 700. |
| Core Losses (at 1.5 T) | Highest of the three grades (not quantified; higher than 3P). | 6 W/kg (moderate; lower than 1P). | 6 W/kg (lowest; significantly better than Somaloy 500 at 12 W/kg). |
| Mechanical Strength (TRS) | ~50 MPa (lowest). | Up to 82.7 ± 13.5 MPa (highest). | ~70 MPa (good, but lower than 3P). |
| Frequency Range | Up to 1000 Hz (less efficient at high frequencies). | Up to 1000 Hz (efficient for mid-to-high frequencies). | Up to 1000 Hz (optimized for high frequencies). |
| Density | ~7.4 g/cm³ (compaction at 600–800 MPa). | ~7.5 g/cm³ (compaction at 600–800 MPa). | ~7.5 g/cm³ (compaction at 600–800 MPa). |
| Cost | Lowest (most economical). | Moderate (higher than 1P, lower than 5P). | Highest (advanced processing). |
| Typical Applications | Basic solenoids, low-cost inductors, simple motor stators. | Automotive solenoids, stator cores for mid-range motors, ignition coils. | High-speed motors, axial-flux motors, high-efficiency inverters. |
| Benefits for Motor Design | Cost-effective for low-performance applications; simple shapes. | High strength for durable components; good balance of losses and permeability; complex 3D shapes. | Lowest core losses for high-efficiency motors; supports high-frequency operation; complex geometries. |
| Limitations | Lower strength and permeability; higher core losses. | Moderate core losses; not ideal for ultra-high-frequency applications. | Higher cost; slightly lower mechanical strength than 3P. |
| Best Suited For | Budget-conscious designs with basic requirements. | Applications needing durability and moderate efficiency (e.g., automotive, industrial motors). | High-performance, high-frequency motors (e.g., EVs, aerospace). |
Applications of Somaloy Materials
| Motors: In the drive motors of new energy vehicles, Somaloy materials enable miniaturization and lightweight designs, enhancing power density. For example, Somaloy soft magnetic composites support axial flux motors in vehicles, effectively reducing the size and weight of the motors, improving power density, and simplifying the motor production assembly process.
| Machine Tool Motors: In spindle drives for CNC lathes and semiconductor processing equipment, the advantages of using Somaloy materials for miniaturization and lightweight designs enable flexible motor magnetic field structures, significantly improving mass production efficiency.
Somaloy Provider
At Tengye, we’re thrilled to be early participants in your new projects. Our passion for magnets extends from material selection and design optimization to providing magnetic solutions. We hope to bring our knowledge and experience to the forefront by actively engaging in your upcoming projects. Work with our magnet experts to get the right magnet solution.
Image Source: Horizontechnology & Mono.ipros & Researchgate
