EN
FR
DE
ES
How to Choose Reactor Core Materials? — Comprehensive Guide to Silicon Steel, Ferrite, and Amorphous Alloys
How to Choose Reactor Core Materials?
— Comprehensive Guide to Silicon Steel, Ferrite, and Amorphous Alloys
In power systems, new energy inverters, and industrial frequency conversion equipment, "reactor core material selection" is a critical decision affecting efficiency, size, and cost. According toIEEE 389 standards, core materials directly determine 40%-60% of reactor losses. This article, based onIEC 60404 andASTM A927 international standards, systematically analyzes the magnetic properties of silicon steel, ferrite, and amorphous alloys, providing a global engineering selection guide.
Content
1. Key Performance Parameters and Selection Logic
● Core Performance Indicators
The core parameters of magnetic materials determine reactor size, efficiency, and temperature rise:
(1)Saturation Flux Density (Bsat):
·Definition:Maximum magnetic flux density a material can withstand (unit: Tesla, T).
·Impact: Higher Bsat reduces core volume for the same inductance (Formula:
). For example, increasing Bsat from 1.5T to 2.0T reduces volume by 25%.
(2)Permeability (μ):
·Definition: Material’s ability to conduct magnetic flux, determining inductance(Formula:
).
·Impact:High μ reduces coil turns, lowering copper losses and costs.
(3)Loss Density (Pv):
·Definition: Hysteresis and eddy current losses per unit volume (Formula:
).
·Impact: Lower Pv improves efficiency and temperature control (IEC 60076-14 requires ΔT ≤65K).
● Material Selection Matrix
Key Requirement | Material Property | Suitable Material |
High-frequency (>10kHz) | Low loss (Pv <5W/m³) | Ferrite (Mn-Zn/Ni-Zn) |
High current (>100A) | High Bsat (≥1.8T) | Silicon Steel (Grain-Oriented) |
Energy efficiency | Ultra-low loss (Pv <1W/kg) | Amorphous Alloy |
Cost-sensitive projects | Cost-effective | Silicon Steel (Non-oriented) |
2. Silicon Steel: High Power Density & Cost Efficiency
● Properties & Advantages
(1)High Bsat (1.8–2.0T): Silicon addition (2%-3.5%) increases resistivity, reducing eddy current losses.
(2)Grain-Oriented (GO) Technology: Aligns grains during rolling, boosting permeability for power-frequency applications.
● Pros vs. Cons
Pros | Cons | Applications |
Low cost (60% cheaper than amorphous) | High losses at >1kHz | Power-frequency reactors (wind/solar) |
High mechanical strength (≥300MPa) | Lower μ than amorphous alloys | High-current filters (IEC 61800-9-2) |
3. Ferrite: Low-Loss Solution for High Frequencies
● Properties & Advantages
(1)Low High-Frequency Losses: Mn-Zn ferrite resistivity minimizes eddy currents.
(2)High μ: Optimized microstructure suits high-frequency inductors (e.g., SMPS).
● Pros vs. Cons
Pros | Cons | Applications |
>98% efficiency at >10kHz | Low Bsat (0.3–0.5T) | Server PFC inductors (EN 62368-1) |
Compact size (50% smaller than silicon steel) | Brittle (prone to cracking) | Telecom transformers |
4. Amorphous Alloy: Ultra-Low Loss & Eco-Friendly
● Properties & Advantages
(1)Ultra-Low Hysteresis Loss: Disordered atomic structure reduces losses to 1/5 of silicon steel.
(2)Sustainability: 80% lower energy in manufacturing (ASTM A927 LCA).
● Pros vs. Cons
Pros | Cons | Applications |
70% lower loss than silicon steel | High material cost (2–3× silicon steel) | Solar inverters (IEC 61683) |
Low temperature rise (ΔT ≤40K) | Difficult machining (special tools) | Energy-efficient reactors (IEC 60076-20) |
In Summary
Conclusion Silicon steel, ferrite, and amorphous alloys require balancing frequency, power density, and lifecycle costs. Amorphous alloys excel in energy-efficient power-frequency applications, while ferrite dominates high-frequency designs. For IEC/IEEE/EN-compliant solutions, contact our technical team for end-to-end services from simulation to prototyping.
Contact Us
LuShan, est.1975, is a Chinese professional manufacturer specializing in power transformers and reactors for50+ years. Leading products are single-phase transformer, three-phase isolation transformers,electrical transformer,distribution transformer, step down and step up transformer, low voltage transformer, high voltage transformer, control transformer, toroidal transformer, R-core transformer;DC inductors, AC reactors, filtering reactor, line and load reactor, chokes, filtering reactor, and intermediate,high-frequency products.
Our power transformers and reactors are widely used in 10 application areas: rapid transit, construction machinery, renewable energy, intelligent manufacturing, medical equipment, coal mine explosion prevention , excitation system, vacuum sintering(furnace), central air conditioning.
Know more about power transformer and reactor :www.lstransformer.com.
If you would like to obtain customized solutions for transformers or reactors, please contact us.
WhatsApp：+86 13787095096
Email:marketing@hnlsdz.com
