1. RESEARCH OVERVIEW (Jan. 2017-Jul. 2019)
Center for Research and Technology - Hellas
Laboratory of Inorganic Materials
RESEARCH OVERVIEW (Jan Jul. 2019)
July 2019

2. Main Research Directions
Appendix A
Development of new and better materials and Processes
Appendix B
Analytical, technical and troubleshooting support on factory projects
Appendix C
Competitor Product Analysis and Benchmarking and Supplier Evaluation

3. Development of new and better materials and processes
A material termed 3P45+ has been developed. The material is analogous in properties to 3P45 but exhibits superior saturation induction at 25oC (575 mT which is ~8.5% higher than 3P45). The technology has been successfully transferred in a pilot batch. Project overview information in Appendix A-Slide A1
3F46+
A material termed 3F46+ has been developed which outperforms in 3 and 5MHz power losses current 3F46 as well as competitor’s P61. The technical improvements have been introduced to production. Project overview information in Appendix A-Slide A2
3F5+
A new material has been developed for the frequency range 3-10MHz that improves 3F5 on the basis of Caobalt which, as found, increases significantly resonance frequency and reduces residual losses. The technical improvements have been introduced to production. Project overview information in Appendix A-Slide A3

4. Development of new and better materials and processes
Within this project in order to cover factory cost saving needs, a process has been developed that enabled the reworking of a 3F5 unneeded batch to a 3F56 quality material. The process has been successfully implemented. Project overview information in Appendix A-Slide A4
4F1+
The aim of this project was to revisit and understand the behavior of an old and never touched 4F1 grade and consequently to investigate the possibilities for its improvement. A new material has been developed that between 3 and 10 MHz outperforms in losses traditional 4F1. The technical improvements have been successfully implemented. Project overview information in Appendix-Slide 5
Thermal Ageing/3F36A
The aim of this project that used as carrier grade 3F36A was to understand and control the magnetic performance instabilities of cobalt containing grades. After extensive experimental ageing series the phenomenon has been understood, the theoretical background has been formed and the achieved knowledge is already implemented during the production and measurement of high frequency cobalt containing grades. Project overview information in Appendix-Slide 6

5. Development of new and better materials and processes
The development of a power MnZn ferrite material with low power losses in particular at the high temperature branch of the power loss curve. More concrete 100kHz-200 mT of ~290mW/cc at 120oC and ~340mW/cc at 140oC are specified. Based on research results a pilot batch with losses of ~360mW/cc at 120oC and 412mW/cc at 160oC has been produced. Project overview information in Appendix A-Slide A7
3C91M
The development of a power MnZn ferrite material specified to have low power losses at low temperatures i.e. lower than 350mW/cc at 0oC and lower than 250mW/cc at 40 and 60oC. The development has been followed by a successful pilot batch production that matched almost exactly the lab results. Project overview information in Appendix A-Slide A8
3C93ΑM
The development of a power MnZn ferrite material with optimal magnetic performance in the temperature region oC. A material that performs better than 3C93 that has been considered as reference has been developed. Project overview information in Appendix A-Slide A9

6. Development of new and better materials and processes
3C95T(AM)
The development of a power MnZn ferrite material with magnetic characteristics similar to 3C95 but specially designed for the automotive industry and besides loss temperature stability (flatness) also thermal ageing stability is required. A wide spectrum of materials became available that allow choices on demand. Pilot batch production experiments verified the laboratory results. Project overview information in Appendix A-Slides A10-1 to A10-4.
3C97T(AM)
The development of a power MnZn ferrite material with magnetic characteristics similar to 3C97 (power loss flatness at high temperatures) but specially designed for the automotive industry and besides loss temperature stability (flatness) also thermal ageing stability is required. An optimized composition has been determined that exhibits no more than 10% variation after ageing. Project overview information in Appendix A-Slides A11-1 to A11-2.

7. Analytical, technical and troubleshooting support on factory projects
Large product densification
The aim of this project was to understand and control the reasons and mechanisms behind the poor densification of large products in comparison to their small counterparts of the same grades. Several doping elements have been evaluated among which some were successful and some others not. It appears that vanadium is a promising dopant in enhancing in particular poor densities and should be evaluated further. Project overview information in Appendix B-Slide B1
3C92 vs. 3G1 densification
The aim of this project was to understand clarify factory observations that while 3C92 products exhibit sufficient densifications, 3G1 products of similar geometry do not. After extensive analyses it has been found that the reasons are not related to the 3G1 powder potential which is very good but due to the fact that the strong iron excess requires very reductive atmospheres that could not be met in the available industrial kilns. Project overview information in Appendix B-Slide B2

8. Analytical, technical and troubleshooting support on factory projects
Thermal Expansion-Product Sticking
The aim of this project was to understand the reasons and mechanisms behind product expansion during the initial firing stadia in order to control it and avoid product sticking therefore allowing for higher furnace loadings and cost savings. The conditions and mechanisms have been established and experimental verification under production conditions is in progress. Project overview information in Appendix B-Slide B3
Stress Sensitivity of Co-containing grades
The aim of this project was to understand the reasons and mechanisms behind the high stress sensitivity exhibited by cobalt containing grades that may alter magnetic behavior when in use by the customer or may lead to the sudden occurrence of internal cracks. Project overview information in Appendix B-Slide B4

9. Competitor Product Analysis and Benchmarking and Supplier Evaluation
General Material Characterisation Facilities
Laboratory’s material analysis and characterization equipment is broadly used within the frame of the cooperation not only for research and development purposes but for any case that may be considered needed. In Appendix C-Slide C1 an overview Table is shown about the global analytical capacities required.
Competitor Studies
Competitor studies are usually related to chemical, structural and morphological investigations on competitor products in order to extract information that might be useful in our development projects. In the Table in Appendix C-Slide C2 a global overview is given on competitor studies carried out during the last 2.5 years
Factory Service
Factory service is related to the provision of analytical, morphological, structural or other information about samples arrived from the factory and concern projects that are entirely taking place in the factory. In the Table in Appendix C-Slide C2 a global overview is given on services for factory projects during the last 2.5 years

10. Competitor Product Analysis and Benchmarking and Supplier Evaluation
Databases and others
Raw material and dopant suppliers are being evaluated and the data are kept in databases so that one can easily evaluate a new supplier or detect fast eventual production disturbances due to raw material quality. In the Table in Appendix C-Slide C3 a global overview is given on raw material evaluations and some other not activities.

11. Appendices

12. Appendix A1

13. Appendix A2

14. Appendix A3

15. Appendix A4

16. Appendix A5

17. Appendix A6

18. Appendix A7

19. Appendix A8

20. Appendix A9

21. Appendix A10-1

22. Appendix A10-2

23. Appendix A10-3

24. Appendix A10-4

25. Appendix A11-1

26. Appendix A11-2

27. Appendix B1

28. Appendix B2

29. Appendix B3

30. Appendix B4

31. Appendix C1 Analytical method Requests (January 2017-July 2019)
Particle Size distribution
255
Specific Surface Area
197
Scanning Electron Microscopy
183
Thermogravimetric Analysis
143
Dilatometry in air and in N2
159
X-Ray Diffraction
122
Powder testing
121
High-temperature XRD 19
Computed Tomography 2

32. Service support projects
Appendix C2
No of.
In specific
Competitor studies 14
DMR51, DMR96, Eaton 3P36, Kyocera, MND5200, Apple TX10, M95, Sumida Fi395, TDK, ACME, Sendust etc.
Service support projects 40
Evaluation of 4A11 cores, 4C65 surface spots, PK cores SEM analysis, Chilisin choke samples investigation etc.

33. Appendix C3 Highlights In specific Chilisin SEM database
Database of polycrystalline microstructure characteristics
Apple TX10
Identification and evaluation of hidden and not visible crack inside TX10 sample via HR- Cone Beam computed Tomography
Amorphous APC cores
Investigation of microstructure and grain structure on selected powder cores
Raw materials database
Morphological evaluation of raw materials (mainly Fe2O3, TiO2 etc)
ZrO2 powders
Investigation of several qualities of used ZrO2 powders