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What Is Soft Magnetic Composite(smc)

Soft Magnetic Composite (SMC) represents a groundbreaking technology poised to revolutionize electrified applications. By encapsulating iron particles with an insulating material, SMCs offer high resistivity and minimal eddy current losses, promising a transformative impact on various industries. By adding an electric current to a carefully designed component made with SMC, an electromagnetic field is created. They are crucial for various applications, such as transformers, alternators, and inductors, where their magnetic properties are essential for efficient operation.

Benefits of Soft Magnetic Composite(SMC)

Flexibility
SMC exhibits isotropic magnetic behavior, making it ideal for three-dimensional (3D) magnetic paths, particularly in AC applications. Its flexibility allows for innovative circuit and motor core designs, resulting in smaller, lighter electronic products. Besides, it is a versatile material that can be molded into various shapes and sizes, allowing for the customization of components to meet specific design requirements.

Cost Reduction
Utilizing powder metallurgy, an eco-friendly technology, SMC helps reduce manufacturing costs and time. Furthermore, eco-friendly powder metallurgy technology in SMC production aligns with modern sustainability goals. This reduces the environmental impact of manufacturing and can result in cost savings through compliance with environmental regulations and reduced waste disposal expenses.

Energy Loss Reduction
The insulating layers in SMC materials significantly reduce eddy current losses, improving energy efficiency, especially in high-frequency applications. This can lead to long-term cost savings for end-users due to reduced power consumption and enhanced performance.

Low Noise
SMC components generate minimal noise due to their low loss characteristics. This attribute ensures a quieter and more comfortable operating environment, especially in settings where reduced noise pollution is essential.

Time Efficiency
SMC components are known for their ease of assembly, which streamlines the manufacturing process and reduces assembly time. This increased efficiency contributes to overall production time savings, enabling manufacturers to meet production deadlines more effectively and cost-efficiently.

Soft Magnetic Composite
Soft Magnetic Composite(SMC)applicatied to robotic dog joints and axial motor.
Stator Spacer
Stator spacer，The parts of pole shoes; it is frequently detachable from the pole shank in a large motor.Stator spacer consist of soft magnetic composition powder Compression molding.
SMC Magnet Yoke
SMC Magnet Yoke is a yoke made of SMC(soft magnetic composite)material. The working principle of the magnetic yoke is based on the law of flux continuity and Ohm's law. When a magnetic field acts on
SMC Yoke Stator Core
Soft magnetic stator core is integrally formed by several teeth and a stator yoke (YASA second generation yoke split winding structure). The winding is placed on the teeth, and the magnetic field
Pole Shoe With Hole
The portion of the pole piece of an electric machine which faces the armature; it is frequently detachable from the pole shank in a large motor.
SMC For Axial Flux Disk Motor Stator
SMC Material for Axial Flux Disk Motor stator
4poles SMC Stator Core
4poles SMC stator core
Somaloy 500/700/1000 Soft Magnetic Composite For Axial Flux Motor
The difficulty in manufacturing the coiled core of the stator of the disc motor is the main reason restricting its application. During the rolling process, there will be the following problems: 1.
Soft Magnetic Iron Core
Composite soft magnetic (Soft Magnetic Composite, SMC) material is a kind of bulk material that is coated with insulating material on the surface of iron powder particles, and then pressed into shape
Axial Flux Motor Cores
The rotor rotates around the stator. The traditional stator core is riveted by silicon steel punching, which is often very heavy, accounting for about 2/3 of the weight of the traditional motor. In
Servo Motor Rotor Core
The inner rotor of the servo motor is purchased with surface-mounted (SPM) rare earth magnetic tiles, which use an arc-shaped permanent magnet glue to solidify on the surface of the motor rotor
Hub Motor Core
New energy vehicles and in-wheel motors have become the forefront of technology and popular industries in recent years.

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We offer our products at competitive prices, making them affordable for our customers. We believe that high-quality products should not come at a premium, and we strive to make our products accessible to all.

Rich experience
Has a long-standing reputation in the industry, which makes it stand out from its competitors. With over many years of experience, they have developed the skills necessary to meet their clients' needs.

High quality products
We always put customer needs and expectations in the first place, refine on, continuous improvement, to seek every opportunity to do better, to provide customers with their expectations of quality products, to provide customers with the most satisfactory service at anytime.

Soft Magnetic Composite Market Outlook from 2023 to 2033

The soft magnetic composite market size reached US$ 41,303.8 million in 2022. Over the forecast period, soft magnetic composite demand is anticipated to rise at a 9.3% CAGR. Total market value is predicted to increase from US$ 44,459.0 million in 2023 to US$ 1,08,392.0 million by 2033.

Attributes	Key Insights
Soft Magnetic Composite Market Size in 2022	US$ 41,303.8 million
Estimated Soft Magnetic Composite Market Value (2023)	US$ 44,459.0 million
Projected Soft Magnetic Composite Market Revenue (2033)	US$ 1,08,392.0 million
Value-based CAGR (2023 to 2033)	9.3%

The soft magnetic composites (SMCs) market is a constantly changing and dynamic area of the more extensive materials and technology for electrical applications. SMCs are cutting-edge materials with exceptional magnetic properties, making them well-suited for several uses in the electrical and electronic sectors. These materials are essential for developing contemporary electrical devices and systems as they are designed to deliver effective magnetic performance while minimizing energy losses.

Several sectors use the SMC, including power electronics, automotive, renewable energy, and telecommunications. SMCs are becoming increasingly popular in the automotive sector, mainly for usage in electric and hybrid vehicles (HEVs).

Materials that aid in developing energy-efficient technology are in greater demand as the importance of sustainability and energy efficiency grows. In this context, SMCs are essential because they make it possible to design and produce electrical components that are more compact & efficient.

To improve the performance of these materials, continuous research and development efforts are what define the soft magnetic composite market. Investigating new applications in developing technologies and emphasizing customization to satisfy particular application requirements are more industry trends.

Worldwide trends in electrification, renewable energy uptake, and electric mobility developments would all impact the soft magnetic composite industry. Cost competitiveness is a problem that market participants frequently encounter, but the growing need for high-performance magnetic materials nonetheless propels innovation and market expansion.

The Unique Properties Of Soft Magnetic Composites

High Permeability And Low Coercivity
SMCs exhibit exceptional magnetic permeability, allowing them to channel magnetic flux efficiently. This property, coupled with low coercivity, enables precise control and manipulation of magnetic fields, essential for various applications.

Customizable Shapes And Sizes
By powder metallurgy techniques, SMC materials offer unparalleled flexibility in shaping and sizing. Manufacturers can tailor these materials to meet specific design requirements, resulting in intricate and customized components for diverse applications.

Superior Performance At High Frequencies
Unlike conventional magnetic materials, SMCs maintain their magnetic properties even at high frequencies. This attribute makes them ideal for applications demanding rapid magnetic field changes, such as in transformers, inductors, and high-frequency power supplies.

High Material Efficiency And Low Production Energy
SMCs are characterized by high material efficiency, as they minimize waste during production. Additionally, the manufacturing process of SMCs requires relatively low energy consumption, contributing to overall sustainability and cost-effectiveness.

Elimination Of Joining Multiple Laminations
Unlike traditional silicon steel laminated cores, SMCs remove the need for joining multiple laminations by interlocks or welding or glue bonding. Both welding and stacking significantly increase the core loss (heat) generated by the device. This simplifies the manufacturing process, reduces assembly time, and enhances overall reliability by eliminating potential points of failure.

3D Magnetic Flux Pathway
SMC components offer the unique advantage of a 3D magnetic flux pathway. Unlike electrical steel motor cores where the flux path is constrained to the plane of the laminations, SMCs allow for multidirectional flux flow, providing greater design flexibility and efficiency in magnetic circuits.

Lower Overall Core Losses At Higher Frequencies
SMCs exhibit lower core losses, particularly at higher frequencies, compared to silicon steel and amorphous materials. The starting material is an insulated fine ferrous powder, which confines losses to individual particle sizes, resulting in improved efficiency and performance in high-frequency applications.

Potential Applications of Soft Magnetic Composite Applications

AC Motors
Soft magnetic composites are used in the design of alternating current (AC) motors. The powder particles are compacted to form laminations for brushless DC (BLDC) motors.

Renewable Energy
SMCs can be used in the renewable energy sector, particularly for the development of efficient and compact motors for solar energy systems. They can be used in off-board power generation, electric pumps, DC conductors, and compressors.

Electric Vehicles
With the increasing trend towards electrification, SMCs play a vital role in the transition to electric vehicles. They are used in traction motors and other parts of electric vehicles to minimize eddy current losses, improve efficiency, and provide superior performance compared to traditional motor cores.

Rotating Machinery
SMCs have become a viable alternative to steel laminations in rotating machinery applications. They have significantly improved low and medium frequency characteristics, making them suitable for rotating machinery, sensors, and fast switching solenoids.
Recent Advances in Soft Magnetic Composites
SMCs have made significant advances due to the demand for improved magnetic materials across industries. Some of the key advances include:

Multifunctional Coatings
One area of innovation in SMCs is the development of multifunctional coatings. These coatings are designed to enhance the energy, electrical, magnetic, and mechanical properties of SMCs. Various coatings can be applied to SMCs, depending on the shape and material of the layers or ferromagnetic powders. Fiber-based soft magnetic composites have been developed by coating Fe fibers with a thin polymer layer, resulting in a material with excellent magnetic permeability.

Development of balanced properties
Researchers are exploring ways to balance high resistivity, high mechanical strength, and high magnetic properties in SMCs. This involves considering the composition of the core and coating materials, or potentially developing new classes of materials.
One such study investigated the preparation of core-shell structured amorphous SiO2 powders for high-performance SMCs. The process included phosphating, sodium silicate coating, and annealing. Results showed an increase in magnetic permeability and a decrease in core losses after annealing at 773 K.

Compact and powerful electric motors
SMC materials enable the design of innovative, compact, and powerful electric motors that can be tailored to specific applications. Their ability to make nonmagnetic materials magnetic has enabled the development of electric motors. These motors are used in electric vehicles (EVs), solenoids, relays, and more.

Types of Soft Magnetic Composite Materials

Powder Cores

These are the most common type of SMCs and are made by compressing magnetic powder into a solid core shape. Powder cores are often used in inductors and transformers because they have high permeability and low core losses.

Polymer-Bonded SMCs

These materials are made by blending magnetic powder with a polymer binder. Polymer-bonded SMCs have better mechanical properties than powder cores and can be molded into various shapes.

Metal-Bonded SMCs

These materials are made by blending magnetic powder with a metal binder. Metal-bonded SMCs have even better mechanical properties than polymer-bonded SMCs and can handle higher operating temperatures.

Nanocrystalline SMCs

These materials are made by embedding small magnetic particles in a nanocrystalline matrix. Nanocrystalline SMCs have high saturation flux density and low coercivity, making them useful in high-frequency applications.

Maintenance Tips For Soft Magnetic Composite Materials

Avoid Exposure To High Temperatures
Soft magnetic composite materials are highly sensitive to temperature changes, particularly at high temperatures. It is recommended to avoid exposing them to temperatures exceeding 150°C. Constant high temperature exposure can cause the material to break down and lose its magnetic properties.

Keep Them Dry
Soft magnetic composite materials are also sensitive to moisture and can corrode easily. It is important to keep them dry and away from water. Proper storage in a dry environment is critical to ensure the long-term performance of the material.

Regular Cleaning
Soft magnetic composite materials may accumulate dirt, oil, and other contaminants over time. Regular cleaning with a soft cloth or brush can help to remove these contaminants and maintain the material's performance.

Prevent Mechanical Damage
Soft magnetic composite materials are prone to mechanical damage, such as cracking or chipping. It is recommended to handle the material with care during installation and to avoid any impact or stress that can cause damage.

Avoid Exposure To Strong Magnetic Fields
Soft magnetic composite materials are designed to have specific magnetic properties. Exposure to strong external magnetic fields can alter these properties and negatively affect the material's performance. It is recommended to keep the material away from strong magnetic fields.

Soft Magnetic Composite: The Basics

Soft magnetic composite particle
Once insulated, the powder is pre-mixed with compaction lubrication to smooth the way for compaction and ejection from the die. The lube gets removed during heat treating afterward.Soft magnetic composites offer possibilities that simply didn't exist before.With the right SMC material your technology can.

Run faster
Consume far less energy
Become more compact & dense
Achieve high permeability
Use higher frequencies

Experience lower core/eddy loss
Definition: Soft magnetic composites are ferromagnetic powder particles ideally coated with a uniform layer of electrical insulating film.Keep in mind that magnetic performance is a function of.

Alloy system used
Density of final part (saturation induction and permeability are influenced by density)
Sintering temperature
Carbon and nitrogen content after sintering

Soft magnetic composites are compacted just like any other powder metal part. Heated die compaction is often used to promote higher density. As noted earlier: Higher density = higher permeability = higher induction.

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Our Factory

Highmag Technology (ShenZhen) Ltd is the subsidiaries of AT&M (Stock Code:000969), which is powerful in new material area and completed IPO in Shenzhen Stock Exchange. We are a professional manufacturer of NdFeB magnet, MIM (metal injection moulding) and SMC (Soft Magnetic Composite). We started magnet manufacturing in Taiwan from 1989 and founded ShenZhen factory in 2001. In 2003, the asset restructuring has become a holding subsidiary. During these years, Highmag has performed excellently and received praise from customers for the technology, manufacturing, service, quality, lead time and cost control. Highmag keeps developing new products and new methods and making full use of geographic advantages--Shenzhen, in order to satisfy the wide requirements of customers in various fields.

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FAQ

Q: What are soft magnetic composite SMC materials?

A: Soft magnetic composite (SMC) materials are made from bonded iron powders. The iron powder is coated with an insulating layer and pressed into a solid material using a die before final heat treatment to cure the bond.

Q: What are the properties of soft magnetic composite?

A: SMCs exhibit exceptional magnetic permeability, allowing them to channel magnetic flux efficiently. This property, coupled with low coercivity, enables precise control and manipulation of magnetic fields, essential for various applications.

Q: What are the applications of soft magnetic composites?

A: Electromagnetic components made from our soft magnetic composite materials can provide unique values to a number of electric applications for automotive as well as industrial use. Pumps (cooling, oil, etc.)

Q: What are the advantages of soft magnetic composites?

A: Design freedom: SMC materials can be molded into any shape, allowing for design freedom in a variety of applications. Reduced energy loss: The insulation layers in SMC materials lower eddy currents, reducing frequency-dependent losses and improving energy efficiency.

Q: What is the process of soft magnetic composite?

A: SMC components are normally manufactured by conventional PM compaction combined with new techniques, such as two step compaction, warm compaction, multi-step and magnetic annealing followed by a heat treatment at relatively low temperature.

Q: How are Soft Magnetic Composite Materials produced?

A: Soft Magnetic Composite Materials are produced by mixing insulating powder particles with magnetic metal particles. The mixture is then pressed, sintered, and annealed to form a solid magnetic structure.

Q: How do SMC materials differ from other magnetic materials?

A: SMC materials differ from other magnetic materials in that they combine the desirable magnetic properties of other materials while also offering lower eddy current losses and higher thermal conductivity. They can also be easily customized to fit specific application requirements.

Q: What is the manufacturing process for SMC materials?

A: The SMC manufacturing process involves the mixing of magnetic metallic powder with a binder material, pressing into a mold under pressure and then sintering in a furnace. Cooling and subsequent grinding process of the part yield the desired particle size distribution and permeability.

Q: What factors can affect the magnetic properties of SMC materials?

A: The magnetic properties of SMC materials can be affected by a variety of factors, including the composition of the magnetic metal powder, the quality of the binder materials, the pressing and sintering process, and the final cooling and grinding process.

Q: What are the typical magnetic properties of SMC materials?

A: SMC materials typically have high permeability, low core losses, high saturation flux density, and low eddy current losses. They can also be customized to have specific magnetic properties to fit specific applications.

Q: What are the benefits of using SMC materials in electric motor applications?

A: SMC materials offer several benefits in electric motor applications, including higher power density, lower core and eddy current losses, higher thermal conductivity, and greater design flexibility. These benefits can result in better motor performance and improved energy efficiency.

Q: Are SMC materials expensive?

A: SMC materials can be more expensive than some other magnetic materials, but their many benefits can make them a cost-effective choice for many different applications.

Q: How can SMC materials be customized for specific applications?

A: SMC materials can be customized by changing the composition of the magnetic metal powder and/or the binder material, adjusting the sintering process, and using different cooling and grinding techniques. These customization options make SMC materials very versatile.

Q: Are SMC materials environmentally friendly?

A: SMC materials can be environmentally friendly, depending on the specific composition of the metal powder and binder materials used. Many SMC materials are recyclable and do not contain hazardous substances.

Q: How durable are SMC materials?

A: SMC materials are typically durable and can withstand a range of environmental conditions. However, their durability can be impacted by factors such as temperature, humidity, and mechanical stress.

Q: What is the maximum operating temperature for SMC materials?

A: The maximum operating temperature for SMC materials can vary depending on the specific composition of the material. Some SMC materials can operate at temperatures up to 200°C.

Q: What is the difference between SMC materials and soft ferrite materials?

A: SMC materials differ from soft ferrite materials in that they have lower eddy current losses and higher thermal conductivity. SMC materials are generally used in more demanding applications where ferrites cannot provide the required performance.

Q: What is the difference between SMC and powdered iron materials?

A: SMC materials typically have higher magnetic permeability and lower core losses compared to powdered iron materials, but they can be more expensive. SMC materials are generally used in more demanding applications where powdered irons cannot provide the required performance.

Q: How do SMC materials perform at high frequencies?

A: SMC materials can perform well at high frequencies, with lower eddy current losses compared to other magnetic materials. This makes them a great choice for .

Q: Can SMC materials be customized for specific shapes and sizes?

A: Yes, SMC materials can be easily customized for specific shapes and sizes by changing the mold used during the pressing process.

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