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Development of Aluminum-Iron Alloys for Magnetic Applications

Magna-Tech P/M Labs with the assistance of the I&I program is using powder metallurgy to develop a soft magnetic aluminum-iron alloy to replace the silicon irons or phosphoreus irons now used in the cores of permanent magnets. The goal of this project is to develop a new soft magnetic iron-aluminum alloy featuring improved magnetic induction, improved structure, more sensitive magnetic properties, lower core losses, and improved tensile strength. Aluminum alloys are expected to be lighter than current alloys, leading to a 10 to 20 percent projected increase in motor efficiency. The use of aluminum-iron alloys represents a new approach in the magnets used in electronic motors. These motors can also be used in electric vehicles. The weight reduction and response would improve the mileage range of the electric vehicle, which is currently a major hindrance to its acceptance in the market place.
Magna-Tech P/M Labs
Lisa Barnett
U.S. Department of Energy
1000 Independence Ave., SW
Washington, DC  20585

phone: (202) 586-2212
fax: (202) 586-7114

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