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  • Engineering the 50 kHz Sweet Spot: Why Nanocrystalline Wins the "Size vs. Heat" War
    Engineering the 50 kHz Sweet Spot: Why Nanocrystalline Wins the "Size vs. Heat" War
    Jan 27, 2026
    In the race to design next-generation Solid State Transformers (SST) and EV power units, the goal is audacious: a 96% reduction in weight. To achieve this massive downsizing, engineers are pushing switching frequencies to 50 kHz and beyond. But this creates a formidable thermal barrier. As every power electronics engineer knows, high frequency usually comes with a heavy penalty: Heat. How do you balance the need for high magnetic flux density (to keep size small) with the need for low core losses (to keep heat manageable)? The 2025 material data reveals that traditional materials are no longer sufficient. It is time to look at the Nanocrystalline solution. The High-Frequency Trade-off: A Material Dead End At 50 kHz, the choice of magnetic core material dictates the success or failure of the thermal management system. Let’s look at the data: 1. Silicon Steel: The Overheating GiantSilicon Steel boasts an impressive Saturation Flux Density(Bs)of 2.03 T, which is great for size reduction in theory.   The Dealbreaker: At 50 kHz, Silicon Steel suffers from disastrous eddy current losses—approximately 200 W/kg. It turns your transformer into a heater, requiring bulky cooling systems that negate any size savings. 2. Ferrite: The Bulky CompromiseFerrite is the traditional "safe choice" for high frequency due to its high resistivity and low loss. The Dealbreaker: Its Saturation Flux Density is pitifully low, hovering around 0.4 T. To handle high power, you need a massive cross-sectional area, resulting in a bulky core that makes the "96% weight reduction" goal impossible. The Nanocrystalline Advantage: Breaking the Trade-off Nanocrystalline C-Cores have become the industry standard for SSTs because they occupy the "Goldilocks Zone" of magnetic properties. They don't force you to choose between size and efficiency—they deliver both.   According to recent comparative testing at 50 kHz: With a saturation level more than 3x higher than Ferrite, Nanocrystalline cores allow for compact, high-power designs that fit within tight mechanical constraints. Some advanced grades even reach 1.4 T. Incredible Efficiency (2-5 W/kg):While Silicon Steel generates ~200 W/kg of heat, Nanocrystalline generates only 2-5 W/kg. This drastic reduction in core loss means simpler cooling, higher system reliability, and significantly higher efficiency. Extreme Permeability:With permeability up to 190,000, these cores ensure superior impedance performance even under high-frequency stress, minimizing leakage inductance. Conclusion: Don't Let the Core Compromise the Design Achieving the weight and efficiency targets of modern Solid State Transformers requires a material that can withstand the stress of 50 kHz without melting down. At Dongguan JH Amorphous, we specialize in precision-wound Nanocrystalline solutions that are engineered to solve this exact thermal dilemma. Whether for EV on-board chargers or grid-tied SSTs, we deliver the balance your engineering demands. Optimal Flux Density(Bs=1.25T):With a saturation level more than 3x higher than Ferrite, Nanocrystalline cores allow for compact, high-power designs that fit within tight mechanical constraints. Some advanced grades even reach 1.4 T. Incredible Efficiency (2-5 W/kg):While Silicon Steel generates ~200 W/kg of heat, Nanocrystalline generates only 2-5 W/kg. This drastic reduction in core loss means simpler cooling, higher system reliability, and significantly higher efficiency. Extreme Permeability:With permeability up to 190,000, these cores ensure superior impedance performance even under high-frequency stress, minimizing leakage inductance. Conclusion: Don't Let the Core Compromise the Design Achieving the weight and efficiency targets of modern Solid State Transformers requires a material that can withstand the stress of 50 kHz without melting down. At Dongguan JH Amorphous, we specialize in precision-wound Nanocrystalline solutions that are engineered to solve this exact thermal dilemma. Whether for EV on-board chargers or grid-tied SSTs, we deliver the balance your engineering demands.
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  • Market Insight: Silicon Steel vs. Nanocrystalline – The "50% Diet" for Your High-Power Transformer
    Market Insight: Silicon Steel vs. Nanocrystalline – The "50% Diet" for Your High-Power Transformer
    Jan 19, 2026
    In the modern power electronics landscape, "Bigger" is no longer "Better." It is just... bigger. For decades, Silicon Steel sheets have been the backbone of the transformer industry. However, as operating frequencies rise and the demand for compact, portable power units explodes, silicon steel is hitting a physical wall. Are you still struggling with bulky, heavy transformers that complicate your thermal management? Today, we analyze the market shift toward Nanocrystalline C-Cores and how this material upgrade is revolutionizing designs in high-stakes fields like Medical X-Ray and Induction Heating. The Core Problem: The Density Dilemma Engineers face a dual challenge: increasing power density while reducing footprint. The Silicon Steel Trap: To handle high power without saturation, silicon steel transformers require significant mass. At higher frequencies (10kHz+), their core losses skyrocket, turning your transformer into a heater. The Nanocrystalline Solution: By switching to Nanocrystalline C-Cores, you aren't just changing materials; you are changing the physics of your design. The "50% Rule": A Game Changer for System Architecture Based on data from our European partnerships, replacing Silicon Steel with Nanocrystalline C-Cores yields immediate, measurable results: Weight & Volume Reduction (~50%):Thanks to high saturation flux density (Bs = 1.25T)combined with high permeability, Nanocrystalline cores can handle the same power transfer in a package half the size and weight of a silicon steel equivalent.   Thermal Mastery:Lower hysteresis and eddy current losses mean less heat generation. This allows engineers to downsize cooling systems (heatsinks/fans), further compounding the space savings.     Sector Spotlight: Where Size Matters Most 1. Medical X-Ray EquipmentModern medical imaging demands mobility. A portable X-Ray unit cannot carry a heavy iron block. Insight: Nanocrystalline C-Cores allow for high-voltage pulse transformers that are lightweight enough for bedside mobile units, yet powerful enough for crisp imaging, all while maintaining strict stability. 2. Induction Heating SystemsThese systems run at high frequencies to heat metals rapidly. Insight: Standard cores struggle with the heat generated at these frequencies. Nanocrystalline cores thrive here, offering stable inductance and minimized losses, ensuring the energy heats the workpiece, not the transformer. Trusted by European Engineering Europe is known for the world's strictest industrial tolerances.We are currently supplying these high-performance C-Cores to partners across Europe who demand: Strict Tolerance Control: Precision cutting to ensure predictable air gaps. Reliable Magnetic Properties: Consistency from batch to batch.   ConclusionIf your design goals involve "Compact," "Efficient," or "Cool," Silicon Steel is likely holding you back. The transition to Nanocrystalline is not just an option; it is the industry standard for next-generation power topology.
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  • Case Study: How a German Heavy-Duty EV Manufacturer Tamed 800V EMI with the JHNO71.5*29.6*30.0 Core
    Case Study: How a German Heavy-Duty EV Manufacturer Tamed 800V EMI with the JHNO71.5*29.6*30.0 Core
    Jan 13, 2026
    Germany's automotive engineering sector is world-renowned for its uncompromising standards, especially in the emerging sector of 800V Heavy-Duty Electrification. Recently, a Munich-based Tier-1 supplier for electric trucks faced a critical hurdle in their 350kW Fast Charging Unit design. This case study explores how our JHNO71.5 provided the high saturation and thermal resilience needed to handle extreme currents where standard Ferrite failed. The Challenge: "The 800V Heat Trap" The German engineering team was developing a high-power DC/DC converter for an electric semi-truck. The shift from 400V to an 800V architecture meant faster charging, but it also brought severe EMI challenges and massive heat generation. Saturation at Peak Load: The charging currents exceeded 400A. Traditional ferrite cores saturated instantly, losing inductance and allowing EMI noise to breach VDE standards. Limited Cooling: The busbar layout was tight. The core needed to handle high DC bias without requiring an active cooling loop directly on the choke. Vibration & Stress: Unlike passenger cars, heavy-duty trucks generate significant vibration. The magnetic core needed superior mechanical protection. They needed a "Heavyweight" magnetic solution—robust, large, and thermally stable. The Solution: The Heavy-Duty JHNO71.5*29.6*30 We introduced the 30, a high-performance Iron-based Nanocrystalline core specifically dimensioned for high-power units. Why this specific core solved the problem: Massive Effective Area (Ae) for High Power:With an Outer Diameter (OD) of 71.5mm and a Height of 30mm, this core offers a significantly larger magnetic cross-section than standard 55mm cores. This prevents saturation even under the massive current spikes typical of heavy-duty charging cycles. High Bs (1.25T) vs. Ferrite:While Ferrite saturates at ~0.4T, our Nanocrystalline material maintains linearity up to 1.25 Tesla. This allowed the German team to reduce the physical size of the filter by 50% compared to a ferrite stack, fitting perfectly into the IP67 aluminum housing. Broadband Attenuation (10kHz - 30MHz):The core provided exceptional insertion loss across the critical frequency spectrum, ensuring the 800V system passed the stringent CISPR 25 Class 5 and commercial vehicle EMC standards (ISO 7637). Thermal Endurance:Operating in a gearbox-adjacent environment, the core's stability from -40°C to +140°C (Curie temp 570°C) ensured zero performance degradation during long-haul climbs in summer heat. Robust "German-Grade" Packaging To meet the vibration requirements of the truck industry, the JHNO71.5*29.6*30.0 is encapsulated in a reinforced PBT (UL94-V0) Case. This square-profile casing protects the nanocrystalline ribbon from mechanical shock and mounting pressure, ensuring the permeability remains constant over the vehicle's 15-year lifecycle. The Outcome: Production Ready By integrating the JHNO71.5*29.6*30.0, the client achieved: 30% Volume Reduction in the EMC filter stage. Full Compliance with 800V EMC regulations without additional shielding. Thermal Safety: The core runs cooler due to lower hysteresis losses compared to alternative metal powder cores. ConclusionIn the era of 800V heavy-duty EVs, "standard" magnetic components are no longer enough. The 30 Nanocrystalline Core offers the brute strength (High Bs) and precision (High Permeability) required by German engineering standards. For more details, check: https://www.amorphousoem.com/product/jhno71529630-nanocrystalline-common-mode-choke-core-for-ev-power-units
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  • Case Study: How an Italian EV Charger Manufacturer Solved Thermal & EMI Challenges with Our 54mm Nanocrystalline Core
    Case Study: How an Italian EV Charger Manufacturer Solved Thermal & EMI Challenges with Our 54mm Nanocrystalline Core
    Jan 11, 2026
    In the competitive landscape of European automotive electronics, thermal management and EMI compliance are the twin hurdles every engineer must clear. Recently, a prominent Tier-1 manufacturer of On-Board Chargers (OBC) based in Turin, Italy, approached us with a critical design bottleneck. This case study details how switching from Ferrite to our Iron-based Nanocrystalline Core (54.0x 50.5 x 18.0 mm) helped them downsize their 22kW charging module while surviving extreme engine compartment temperatures. The Challenge: Saturation at High Temperatures The Italian engineering team was designing a high-density DC/DC converter stage for a new electric hypercar. They faced two specific problems using traditional Mn-Zn Ferrite cores: Thermal Derating: At the target operating temperature of 120°C, the Ferrite cores were losing significant permeability, leading to EMI filter failure. Size Constraints: To prevent magnetic saturation under high current spikes, they had to stack multiple ferrite cores, which violated the strict height restriction of the OBC housing. They needed a solution that offered high saturation flux density (Bs) and stable inductance in a compact footprint. The Solution: High Bs Nanocrystalline Technology After reviewing their magnetic circuit requirements, we proposed our Nanocrystalline Toroidal Core (Model: 54.0). Here is why this specific core was the perfect fit for their application: 1.25T Saturation Flux Density (Bs): Unlike Ferrite (Bs ~0.4T), our iron-based nanocrystalline material handles three times the flux density. This allowed the Italian team to replace two stacked ferrite cores with a single Nanocrystalline unit, reducing weight and volume immediately. Extreme Thermal Stability: With a Curie Temperature of 570°C and a crystallization temperature of 510°C, the core’s magnetic properties remain virtually unchanged from -40°C to +140°C. Superior Inductance per Turn: The core delivers an AL value of ≥ 100.0 µH (at 1kHz, 0.3V). This high impedance allowed the engineers to achieve the required Common Mode attenuation with fewer wire turns, further reducing copper loss (I²R). Robust Packaging for Automotive Standards Reliability is non-negotiable in the EU market. The Italian client was particularly impressed with the encapsulation. The core is housed in a Square-Top Seam Black PBT Case (Polybutylene Terephthalate). Material: UL94-V0 rated PBT. Temperature Rating: Certified for continuous operation up to 140°C. Mechanical Protection: The rigid case protects the delicate nanocrystalline ribbons from winding stress, ensuring the mechanical pressure does not degrade the magnetic permeability (magnetostriction effect). The Result: Successful EMC Certification By integrating the 54.0mm Nanocrystalline core, the client successfully: Reduced Component Height: Met the 20mm clearance requirement (Core height is 18.0mm). Passed CISPR 25 Class 5: The high permeability at 10kHz–150kHz solved their low-frequency noise issues. Enhanced Durability: The effective cross-sectional area (Ae = 168.48 mm²) provided robust performance without saturation during load dump transients. ConclusionFor power electronics engineers struggling with space constraints and high-temperature environments, traditional materials often fall short. As proven by our Italian partners, switching to High-Bs Nanocrystalline cores is not just an upgrade—it is a necessity for next-gen EV power electronics. Looking for high-performance magnetic cores? Check our full datasheet for the 54.0mm series or contact our engineering team for custom samples. For more details, check: https://www.amorphousoem.com/product/jhno-nanocrystalline-common-mode-choke-core-for-ev-power-units
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  • 2025 Global Soft Magnetic Materials Price Matrix and Technical Evolution Depth Research Report
    2025 Global Soft Magnetic Materials Price Matrix and Technical Evolution Depth Research Report
    Dec 25, 2025
    Table of Contents 1. Market View ..................................................................................................... 2 1.1 Global Drivers: Power Electronics, EV, 5G, and AI ......................................... 2  1.2 Market Size Projections: 2025–2029 CAGR Analysis ..................................... 2  1.3 Material Selection as a Key Variable in Supply Chain Optimization ............... 2 2. 2025 Mainstream Soft Magnetic Core Price Benchmarks ........................... 3  2.1 Standardized Price Matrix for Industrial-Grade Bulk Orders ........................... 3  2.2 Application Fields and Core Performance Advantages by Material .................4 4. Iron-Based Nanocrystalline Cores: The High-Efficiency Benchmark ........ 5  5. Ferrite Materials: Cornerstones of High-Frequency Domains .................... 6  6. Sendust Cores: Balancing Performance and Stability ................................ 7 7. Permalloy: Noble Materials for Precision and Shielding ............................. 8 8. The Market Anchors: Silicon Steel and Amorphous Alloys ........................ 9   9. Macro Drivers of Core Pricing in 2025 ......................................................... 10      10. Technical Parameter Comparison (2025 Summary Table) ...................... 11 11. Conclusion and Industry Outlook .............................................. ............... 11 12. About JH Amorphous .................................................................................. 12 13. References .................................................................................................... 12    If you are interested full report, contact julia@amorphousoem.com.    Market View The rapid evolution of global power electronics, electric vehicles (EVs), 5G communications, AI and renewable energy infrastructure has placed unprecedented demands on the performance and cost of magnetic materials.               In the market of 2025, soft magnetic materials are not only the core carriers for energy conversion and signal processing but also critical variables in supply chain cost optimization. According to the latest industry estimates, the global magnetic materials market size reached approximately USD 36.52 billion in 2025 and is expected to maintain a CAGR of 7% to 8.64% over the next decade. This growth is primarily driven by the extensive penetration of soft magnetic materials in electronic devices and power generation, where material selection directly dictates system power density and thermal management strategies. Soft magnetic materials encompass a variety of categories, ranging from low-cost silicon steel to high-performance iron-based nanocrystalline, ferrites, Permalloy, and high flux cores. In 2025, the market focuses not just on raw material costs but emphasizes the integrated cost-benefit ratio brought by technological advancement. For instance, the core loss of iron-based nanocrystalline materials at 100 kHz is nearly 1,000 times lower than that of traditional silicon steel. This generational performance gap means that in high-frequency applications, even with a higher unit price, nanocrystalline materials significantly improve overall cost-performance by enabling system-level lightweighting and reducing cooling costs.   Overview of Mainstream Soft Magnetic Core Price Benchmarks (2025) Before analyzing specific materials, it is essential to establish a standardized price comparison matrix. The following data is based on average quotes for global industrial-grade bulk orders and suppliers investigation in China, Ex work, with units unified in USD/Kg to reflect the relative market positioning of different materials. The price is for reference only, will be different based on QTY. , shapes, electric specifications and business terms.   Material Type Price Range (USD/Kg) Main Application Fields Core Performance Advantages GOES (Grain-Oriented Electrical Steel) 1.15 – 4.06 Large transformers, grid infrastructure High saturation induction (Bs), low cost CRNGO (Non-Oriented Electrical Steel) 1.15 – 6.00 Electric motors, generators Isotropic properties, high-speed efficiency Iron-based Amorphous Cores 2.50 – 8.00 Distribution transformers, reactors, motors Extremely low standby loss, 50Hz~1KHz Iron-based Nanocrystalline 6.00– 45.00 EV charging piles, inverters, EMC filters, UPS, Data Center, SMPS High permeability, wide frequency range (1K~100K Hz) Mn-Zn Ferrite 1.20 – 6.00 Switched-mode power supplies (SMPS), UPS Extremely high resistivity, mature process  <5MHz Ni-Zn Ferrite 2.20– 12.00 High-frequency EMI, RF applications Ultra-high frequency stability 2~70MHz Sendust Powder 2.80 –6.50 Powder metallurgy feedstock >8kHz Permalloy (1J50/1J85) 30.0- 142.00 Precision sensors, magnetic shielding 20~30kHz   Iron-Based Nanocrystalline Cores: The Performance Benchmark for High-Efficiency Power Iron-based nanocrystalline materials represent the pinnacle of contemporary soft magnetic technology. The production involves spraying a molten iron-based alloy at a rate of 10^6 K/s onto a high-speed rotating cooling roll to form an amorphous ribbon only 12 to 30 microns thick, followed by precise heat treatment to induce the precipitation of grains 10 to 15 nanometers in diameter. This unique dual-phase structure grants the material high saturation magnetic induction (Bs 1.25 T) and ultra-high initial permeability (80,000 ~190,000).       Cost Composition and Market Pricing In 2025, the price of nanocrystalline cores is heavily influenced by production thickness, ribbon width, and post-processing (such as core cutting or coating). Industrial bulk quotes for finished cores typically range between USD 6.00 and 45.00 per kg. If examining only the raw material ribbons (e.g., the 1K107 series), the price range is more concentrated between USD 6 and 13.48 per kg. The market premium for nanocrystalline cores in 2025 stems from their complex processing chain. Cut Core processes, which significantly improve assembly efficiency and optimize magnetic leakage, often command a unit price more than 50% higher than toroidal wound cores.  Furthermore, because nanocrystalline ribbons are extremely thin and brittle, the requirements for insulation coatings and protective casings are stringent, forming a non-negligible part of the finished unit price.   The Economic Logic: Nanocrystalline vs. Traditional Materials From a techno-economic perspective, although the unit price of nanocrystalline is 5 to 10 times that of ordinary silicon steel, its application in weight-sensitive sectors like EV traction inverters can reduce transformer volume by 50% and weight by 40%. This "volume-for-efficiency" logic has become highly attractive under 2025 high-energy-efficiency standards. Research shows that at 100 kHz, the loss per unit volume of nanocrystalline cores is far lower than that of Mn-Zn ferrites, making it nearly the only viable solution for megawatt-level high-power high-frequency transformers.   Macro Drivers Influencing Core Pricing in 2025 1. Chinese Supply Chain Dominance: China remains the production hub, accounting for 94.67% of global trade in iron-based nanocrystalline. This concentration makes global prices highly dependent on Chinese electricity costs and export policies. 2. Trade Barriers: Plans by the US to impose 25% to 40% tariffs on metals from over 150 countries starting August 2025 have caused sharp regional price disparities for identical specifications. 3. Energy Intensity: Sintering ferrites and refining silicon steel are energy-intensive. Fluctuations in industrial electricity prices in Europe and SE Asia provide strong support for manufacturing costs.  
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  • Amorphous vs. Nanocrystalline Cores: The Critical Selection for EVs and PV Inverters
    Amorphous vs. Nanocrystalline Cores: The Critical Selection for EVs and PV Inverters
    Dec 11, 2025
      The relentless push toward electrification—from high-performance Electric Vehicle (EV) power control units to grid-optimizing Photovoltaic (PV) inverters—is uniformly demanding components that can handle higher switching frequencies, increased power densities, and extreme efficiency. When system frequencies push past conventional limits, traditional ferrite materials often become the bottleneck, introducing significant losses. For R&D engineers, selecting the right soft magnetic material is not just a component swap; it's a critical decision that dictates the product's performance, size, and ultimate cost. Amorphous and Nanocrystalline materials are the key contenders in this high-stakes selection battle.   1. The Deep Dive: How Material Structure Defines High-Frequency Performance Both Amorphous and Nanocrystalline cores achieve their characteristic exceptionally high permeability  and ultra-low core loss  due to their unique microstructures:   Amorphous Cores: The atoms are in a disordered, non-crystalline state, which eliminates grain boundaries and effectively minimizes eddy current losses. Typically iron-based, amorphous materials boast a high Saturation Magnetic Flux Density (Bs) (up to 1.6T), making them highly suitable for high-current, high-power applications where minimizing volume is paramount.   Nanocrystalline Cores: These are created by subjecting amorphous alloys to a precisely controlled annealing process, resulting in ultra-fine grains (only 10 nanometers in size). This structure nearly eliminates effective magnetic anisotropy, leading to the lowest loss and highest permeability among soft magnetic materials, especially across the mid-to-high frequency spectrum.   Here is a quick reference table comparing key parameters for engineers:   Performance Parameter Traditional Ferrite Amorphous Core (Fe-based) Nanocrystalline Core (Fe-based) Design Significance Saturation Flux Density (Bs)  0.4-0.5T  1.5-1.6T 1.2-1.3T Determines transformer/inductor volume (Higher Bs allows smaller size). Operating Frequency Range Mid-to-High Freq. (>100kHz) Mid-to-Low Freq. (<50 kHz) Wideband (10 kHz to 10 MHz) Defines system efficiency and switching capability. Permeability (ui) approx 1000~5000 approx 10000~50000 Up to 190000 Critical for common mode choke effectiveness and turn count. Core Loss (Pv) High (at high frequencies) Low Extremely Low Directly impacts heat generation and system reliability.   2. Key Applications: Efficiency Breakthroughs in Automotive and Solar EV Power Control: The Key to Cooling and Filtering As On-Board Chargers (OBCs) and DC-DC converters push past 100kHz, the ultra-low loss of nanocrystalline materials makes them the preferred choice for main transformers and resonant inductors, significantly reducing thermal dissipation and boosting efficiency.   For Electromagnetic Compatibility EMC, EV control units generate substantial high-frequency noise. Nanocrystalline cores, with their exceptionally high permeability, are the ideal material for manufacturing high-performance Common Mode Chokes (CMCs), effectively suppressing noise across the 10 kHz to 10 MHz range.     PV Inverters: Balancing Power and Efficiency Amorphous alloys are frequently used in large-current filter inductors within high-power PV systems. Their high Bs and excellent low-frequency loss characteristics allow them to handle large current swings in a smaller form factor. In modular inverters targeting higher power density, Nanocrystalline is adopted in high-frequency transformers and CMCs to maximize conversion efficiency and overall system compactness.     3.  Grasping Future Design Trends   While Amorphous cores remain vital in large-power filtering and lower-frequency applications due to their high saturation flux density and cost advantages, Nanocrystalline cores are rapidly becoming the default solution for high-frequency power electronics driven by SiC/GaN platforms. This shift is driven by their ultra-low loss and superior permeability across a wide bandwidth. Engineers must precisely balance operating frequency, thermal limits, and power density targets when finalizing their material selection.   The future will demand even higher system frequencies, placing greater pressure on soft magnetic materials. Continuous optimization of nanocrystalline core performance will be central to ensuring the long-term reliability of high-performance power electronics systems.   Is your next high-frequency, high-power project bottlenecked by magnetic core selection?   As a specialized manufacturer of high-performance Amorphous and Nanocrystalline soft magnetic materials, Dongguan JH Amorphous controls the core technology from ribbon to precise thermal processing. We provide customized core solutions tailored specifically to your OBC, DC-DC, or PV inverter design needs, guaranteeing efficiency improvements and size optimization.   We invite you to visit our website  today or send your detailed design specifications to our engineering team. Let our professional soft magnetics experts provide you with the selection advice and sample support you need to unlock the next level of performance for your product!
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  • How Magnetic Materials Shape the Future of Liquid-Cooled 8.5 kW Server Power Supplies
    How Magnetic Materials Shape the Future of Liquid-Cooled 8.5 kW Server Power Supplies
    Dec 09, 2025
    Engineering Insights into EMI Filters, PFC Chokes, and the Role of 1K107B Nanocrystalline vs. 1K101 Amorphous Cores As power supplies for data centers and AI servers enter the 8.5 kW to 12 kW range, engineers face a significant architectural shift. Liquid cooling is becoming mainstream, switching frequencies are rising, and power density is pushing beyond 100 W/in³. These trends have brought a new bottleneck to the front of PSU design: Magnetic materials — especially those used in EMI filters and PFC chokes — increasingly determine the feasibility of next-generation liquid-cooled power architectures. A commonly referenced teardown image of an 8.5 kW server PSU illustrates this point clearly: EMI Filter positioned at the thermal entrance PFC Choke (TTPFC) running at high frequency Bulk Capacitors in the center LLC stage and main transformer toward the cold plate regions Compact mechanical layout optimized for liquid cooling This configuration highlights a fundamental truth: when switching frequency increases and heat-spreading paths become constrained, magnetic core loss becomes the dominant thermal source in these front-end components.   1. Why Liquid Cooling Makes Magnetic Materials More Critical Liquid cooling greatly improves heat extraction from power semiconductors (GaN, MOSFETs, SR devices). However, many magnetics — especially EMI filters and PFC inductors — are not mounted directly on cold plates. In an 8.5 kW PSU: The cold plate is reserved for semiconductors and key transformers EMI and PFC inductors sit in restricted airflow zones Their thermal paths are poorly coupled to the liquid cooling loop This leads to an important engineering observation: Magnetic components now rely far more on intrinsic core loss performance, rather than on mechanical cooling solutions. As a result, differences between materials such as 1K107B nanocrystalline and 1K101 amorphous become significantly amplified.   2. The Rise of High-Frequency PFC: A Stress Test for Magnetic Materials Typical PFC switching frequencies have increased from: 20–30 kHz → 40–70 kHz → approaching 100 kHz in TTPFC designs. This shift improves power density but also raises: AC flux density Switching ripple High-frequency harmonics Core temperature Because of this, the high-frequency loss curve becomes the dominant factor in magnetic selection.   Key Findings: 1K107B Nanocrystalline Core Lower high-frequency core loss More stable permeability Better temperature behavior Enables smaller inductors Reduces hotspot temperature by 10–20°C in many PSU designs   1K101 Amorphous Core Core loss increases steeply above 20–40 kHz Larger physical size required Higher hotspot temperatures Less suitable for compact, liquid-cooled PSUs In practice, many 6–8 kW PSU designs using 1K101 encounter either:✔ Excessive temperature rise✔ Oversized inductorsBoth of which limit system scalability.   3. Material Selection for EMI Filters in Liquid-Cooled PSUs EMI filters are especially sensitive to high-frequency noise and temperature constraints. They require: High permeability Low HF loss Surge robustness Stable inductance under thermal stress Nanocrystalline material (1K107B) offers advantages in: Broadband EMI suppression Maintaining inductance at elevated temperatures Reducing size for compact front-end layouts Lower incremental loss across switching harmonics Therefore: In modern 8.5 kW PSU designs, EMI filters increasingly favor 1K107B over 1K101.   4. Where Amorphous Material Still Excels Despite the advantages of nanocrystalline cores in high-frequency stages, 1K101 amorphous remains the preferred material for: Current transformers (CTs) Low-frequency PFC input inductors Large magnetic flux swing operations HVDC filtering stages High saturation flux requirements This means: The shift is not about replacing amorphous materials,but about using each material where it performs best.   5. Industry Trends: Migration Toward High-Frequency-Optimized Materials Across major server OEMs and hyperscale power suppliers, engineering teams are converging on a clear material strategy for liquid-cooled PSUs: ✔ EMI Filter → 1K107B Nanocrystalline ✔ PFC Choke (TTPFC) → 1K107B Nanocrystalline ✔ Current Transformers → 1K101 Amorphous ✔ Input Inductors → Mixed (depending on ripple and frequency) A shared viewpoint is emerging: As PSU power density surpasses 100 W/in³,magnetic material selection becomes just as critical as topology selection.   🗣️ Discussion: What Will Be the Next Bottleneck? As server PSUs evolve from 8.5 kW → 10 kW → 12 kW, liquid cooling and GaN technologies will continue to push the boundaries of power density. But magnetics remain key thermal contributors — especially in front-end EMI and PFC stages. A question for engineers designing next-generation AI server PSUs: Which magnetic component do you expect to become the next limiting factor in ultra-dense liquid-cooled designs? EMI choke? TTPFC inductor? LLC transformer? Or the magnetic materials themselves?   Your insights and field experiences are welcome.
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  • How Reliable Are Nanocrystalline Cores Under Temperature Extremes?
    How Reliable Are Nanocrystalline Cores Under Temperature Extremes?
    Nov 26, 2025
    At JH Amorphous, we are committed to ensuring that our products perform reliably, even in the most demanding environments. Our latest high/low temperature environmental reliability test has once again proven the exceptional temperature stability of our nanocrystalline toroidal magnetic cores. In this test, we subjected three of our nanocrystalline cores (LF-T322010-655R, LF-T402515-646R, LF-T311912-642R) to temperature shock tests at 0–5℃ and 80℃. The results were impressive, confirming the outstanding reliability of our cores under temperature extremes.   What Did We Test? 🔍 We conducted a full temperature cycle involving 25°C → Low Temperature → Recovery → High Temperature → Recovery. Throughout this process, the inductance variation stayed within approximately ±1%, showcasing the excellent magnetic performance stability of our cores across varying temperatures. (See the full data in the technical report.)   Why Does This Matter for Engineers? Exceptional Temperature Stability: The cores maintained excellent magnetic performance under both low and high temperatures, making them ideal for use in automotive electronics, power supply systems, and other high-reliability applications. Greater Safety Margins: The ability to perform reliably across a wide temperature range provides added safety margins for engineers designing mission-critical systems. Consistency Across Batches: With minimal inductance variation across batches, our cores deliver strong product consistency, ensuring low batch-to-batch variation — a crucial factor for ensuring stable EMC/EMI performance in your designs.   How Did We Conduct the Test? Our rigorous testing methodology follows a step-by-step process to simulate real-world temperature cycles: Room-temperature measurement → Exposed to 0–5°C for 1 hour → 30-minute recovery at room temperature → Re-measurement Room-temperature measurement → Exposed to 80°C for 1 hour → 30-minute recovery at room temperature → Re-measurement Both tests showed that all three cores demonstrated minimal inductance drift, confirming the superior temperature reliability of nanocrystalline materials.   Why Should Engineers Care About This? Nanocrystalline cores are low-loss and high-permeability, making them ideal for energy-efficient and high-performance applications. However, their temperature reliability is a key factor that sets them apart in demanding environments. In applications such as automotive systems, industrial equipment, and high-performance power electronics, our nanocrystalline cores deliver stable performance under temperature fluctuations. This makes them a reliable choice for engineers who require consistent, high-quality performance in their designs — even under extreme temperature conditions.   Conclusion: Our nanocrystalline cores not only provide low-loss, high-permeability, and superior performance, but also excel in temperature stability. Whether exposed to low or high temperatures, these cores remain reliable and stable, ensuring the long-term performance of your electronic systems. For engineers looking for magnetic material solutions that are high-temperature stable, low-temperature reliable, and batch-consistent, our nanocrystalline cores are an ideal solution. Contact us today to learn more about how we can help support your projects with high-performance, temperature-resilient materials.   Looking for Reliable Magnetic Materials for Your Next Project? If you're designing high-performance electronics and need stable, temperature-resistant magnetic materials, we’re here to help! Reach out to us to discuss how our nanocrystalline cores can meet the demands of your most challenging designs.
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  • Why Magnetic Core Material Plays a Crucial Role in Inductor Performance: A Deep Dive
    Why Magnetic Core Material Plays a Crucial Role in Inductor Performance: A Deep Dive
    Nov 20, 2025
    Now fast-paced world of electronics, engineers are constantly faced with the challenge of optimizing circuit performance while maintaining compactness and energy efficiency. One crucial, yet often overlooked, component in these designs is the magnetic core used in inductors. The material of the magnetic core can dramatically influence the inductor’s performance, particularly in high-frequency applications. This blog will explore how different magnetic core materials impact inductor performance, why choosing the right material is critical, and how these materials affect the efficiency and longevity of your electronic devices.   The Importance of Magnetic Core Material Magnetic cores play a vital role in the function of inductors. They influence inductance, energy storage, efficiency, and power losses. The performance of an inductor is highly dependent on the magnetic material it’s made from, and the right choice of material can make a significant difference in how well the device operates across different frequencies and power levels. There are several materials commonly used for magnetic cores in inductors, such as ferrite, silicon steel, and nanocrystalline alloys. Each material comes with its own set of advantages and limitations, making it essential for engineers to understand the material properties in order to make the right choice for a given application.   How Different Magnetic Core Materials Affect Performance Mn-Zn Ferrite CoresFerrite cores are made from iron oxide combined with other metals, and they are widely used in high-frequency applications like switch-mode power supplies and transformers. They offer relatively low eddy current losses at high frequencies, making them suitable for circuits operating in the kilohertz (kHz) to megahertz (MHz) range. Additionally, ferrite cores have high magnetic permeability, which means they can store more magnetic energy with relatively low losses, improving circuit efficiency. However, Mn-Zn ferrite cores have limitations at very high frequencies, where losses can increase due to core material saturation. Ferrite cores are also less efficient at very low frequencies, which makes them less suitable for power transformers or circuits that require low-frequency performance.   Nanocrystalline CoresNanocrystalline cores, a newer material in magnetic technology, offer exceptional performance in high-frequency applications. These cores are made from iron and other elements arranged in a nanocrystalline structure, which allows them to exhibit significantly higher magnetic permeability compared to ferrite cores. Nanocrystalline cores provide lower losses and higher efficiency in high-frequency circuits, such as power inductors in high-frequency switching power supplies. Their higher saturation flux density makes them particularly useful for high-power applications, where maintaining performance at higher current levels is essential. The main advantage of nanocrystalline cores over ferrite is their ability to operate with up to 30% lower high-frequency losses. They also maintain low hysteresis losses even at very high frequencies (several hundred kHz), making them ideal for applications in the 5G telecommunications, electric vehicles (EVs), and data centers.   Silicon Steel CoresSilicon steel is another material that has been used for decades in power transformers and other low-frequency applications. Its relatively low magnetic losses make it suitable for power transformers operating at 50-60Hz in traditional power grids. However, silicon steel’s performance at higher frequencies is limited due to significant eddy current losses. This makes it less suitable for high-frequency applications, such as modern power electronics or devices that operate in the kHz-MHz range.   The Mechanism Behind Magnetic Core Performance The performance of magnetic cores in inductors is largely determined by the following factors: Magnetic Permeability: The ability of a material to support the formation of a magnetic field. Higher permeability means better energy storage capacity and lower losses. Hysteresis Losses: The energy lost when the magnetic material is magnetized and demagnetized. Materials with lower hysteresis losses are more efficient. Eddy Current Losses: Induced currents within the core material that cause heat loss. High-frequency applications require materials that minimize these losses. Saturation Flux Density: The maximum magnetic field strength the material can handle before its magnetic properties break down. A higher saturation flux density means the material can handle higher currents without losing performance.   Quantifying the Performance Gains Nanocrystalline materials reduce high-frequency losses by up to 30% compared to Mn-zn ferrite cores. They also provide 2-3 times higher permeability, which means more efficient energy storage and enhanced inductor performance in high-power, high-frequency applications. These materials are particularly useful in systems requiring low hysteresis loss and high-frequency operation (several hundred kHz), which are essential in modern electronics like switch-mode power supplies, 5G networks, and electric vehicles (EVs).   Choosing the Right Core Material for Different Applications When selecting a magnetic core for an inductor, engineers must consider the specific requirements of the application: Switch-Mode Power Supplies (SMPS): Ferrite and nanocrystalline cores are ideal for high-frequency operation and minimizing losses. Electric Vehicles (EV): Nanocrystalline cores, with their high saturation flux density and low losses, are essential for handling large currents in high-power applications. 5G Networks: High-performance cores, such as nanocrystalline, offer superior efficiency for handling high-frequency signals while minimizing power loss. Data Centers: For high-speed communication and efficient power conversion, nanocrystalline cores are increasingly being used to improve system efficiency.    The Critical Role of Magnetic Core Material in Inductor Design Magnetic core material plays a critical role in the performance of inductors and the overall efficiency of electronic circuits. By selecting the appropriate core material—whether it’s ferrite, nanocrystalline, or silicon steel—engineers can ensure that inductors function efficiently across different frequencies and power levels. Understanding the benefits and limitations of each material is essential for optimizing circuit designs in today’s high-performance, energy-efficient electronic systems. As technologies like 5G, electric vehicles, and AI data centers continue to evolve, the importance of choosing the right magnetic core material will only grow.   What’s Your Biggest Challenge in High-Frequency Inductor Design? In the fast-evolving world of electronics, engineers are continuously tasked with pushing the limits of technology. Whether you’re designing power supplies, communication systems, or next-gen EVs, understanding the relationship between magnetic core material and inductor performance is key to achieving optimal results.   Let us know your thoughts, DM us. 
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  • Why Do Nanocrystalline Cores Stay Rock Solid Under High Current? — The Truth Behind Magnetic Saturation
    Why Do Nanocrystalline Cores Stay Rock Solid Under High Current? — The Truth Behind Magnetic Saturation
    Nov 13, 2025
    Discover why nanocrystalline cores outperform traditional magnetic materials under DC bias and high current. This article explains their anti-saturation behavior, supported by real customer cases and B-H curve analysis for transformers, inductors, and EMC filters. In magnetic component design, one of the biggest challenges engineers face isn’t cost — it’s magnetic saturation. Under high current or DC bias, once the core saturates, inductance drops, losses rise, and EMI performance collapses.   Recently, one of our EV charger clients faced this exact problem. Their common mode choke was overheating and failing EMI tests. Testing revealed that the high-permeability permalloy core was severely saturated under DC bias, leading to a sharp decline in effective permeability. We suggested switching to nanocrystalline cores.  But after reviewing the B-H curves, the difference was undeniable: High-μ alloys magnetize quickly but saturate under strong magnetic fields; Nanocrystalline materials maintain permeability stability even under heavy DC bias; Low-μ ferrites resist saturation but lack sufficient inductance for high-power systems. The results were remarkable:✅ EMI margin improved by 40%✅ Core temperature dropped by 15°C✅ No redesign required ✳️ Why Nanocrystalline Cores Perform Better Nanocrystalline alloys feature ultra-fine grains (10–20 nm), resulting in smooth domain wall motion, low hysteresis loss, and stable permeability.Key properties include: High saturation flux density (1.2 T) Medium to high permeability (μ ≈ 80K ~ 190K) Excellent DC bias tolerance Strong temperature stability ( -40 ~ 140 degree) That’s why nanocrystalline cores are ideal for: Common mode chokes (EMC filters) Power inductors High-frequency transformers EV chargers, inverters, and power modules In short, nanocrystalline materials achieve the perfect balance between permeability and saturation resistance — keeping magnetic cores rock solid under current.   🏭 About JH Amorphous JH Amorphous is a professional manufacturer specializing in nanocrystalline and amorphous magnetic cores, serving global customers in transformers, inductors, common mode chokes, and EMC filter applications.We focus on delivering high-performance, customizable core solutions to help engineers design magnetic components that remain stable and efficient even under high current, high frequency, and harsh conditions.   👉 Visit our website or contact our export team to learn more about JH Amorphous products and technical support.JH Amorphous — Your Trusted Partner in Advanced Magnetic Materials.
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  • How Nanocrystalline Cores Redefine Efficiency and Size in Power Electronics
    How Nanocrystalline Cores Redefine Efficiency and Size in Power Electronics
    Nov 03, 2025
    In power electronics, the eternal challenge is achieving higher power density, lower losses, and greater efficiency — all in smaller, lighter systems. For decades, engineers have pushed the limits of magnetic materials to make this possible. Now, a new generation of material — the nanocrystalline alloy — is unlocking what once seemed impossible. It’s not just an upgrade to existing cores. It’s a paradigm shift in electromagnetic design — enabling solid-state transformers, EV fast chargers, and next-generation power converters to go further, faster, and cooler.   1. The Efficiency Equation: Where Every Watt Counts In modern energy systems, even a 1% gain in conversion efficiency can translate to megawatt-hours of saved energy and millions of dollars in reduced operating costs. Traditional materials — silicon steel or ferrite — struggle as switching frequencies increase. Their eddy current losses rise exponentially, creating excessive heat and forcing bulky cooling systems. Nanocrystalline alloys rewrite that equation: High resistivity (~120 μΩ·cm) drastically cuts eddy current losses. Fine grain size (<20 nm) reduces domain wall motion losses. Uniform microstructure ensures consistent magnetic performance even under thermal stress. As a result, core loss can be reduced by up to 70%, directly improving overall system efficiency — a critical advantage for solid-state transformers (SSTs), DC/DC converters, and high-frequency inverters. In power electronics, less heat = less waste = longer life.That’s why nanocrystalline cores aren’t just about performance — they’re about system reliability.   2. Shrinking the Core, Expanding the Possibilities Every watt saved also means less magnetic material needed. With permeability levels in the range of 10⁵–10⁶, nanocrystalline cores allow designers to achieve the same magnetic flux with 40–70% less volume compared to ferrite or amorphous cores. That translates to: Smaller transformers and inductors Lighter EV charger modules Compact high-density data center power supplies And because nanocrystalline maintains stable permeability across frequencies from 1 kHz to 100 kHz, engineers no longer need to trade size for efficiency. In the race to miniaturize power systems, nanocrystalline alloys have become the ultimate enabler.   3. Real-World Impact: From Fast Chargers to AI Power Grids Let’s look at some numbers: A 30 kW EV fast charger requires around 3–4 kg of nanocrystalline core, reducing system losses by up to 2%. A 100 kVA solid-state transformer using nanocrystalline can be 40% smaller and 15–25°C cooler than one with amorphous cores. In large data centers, even a 1% boost in efficiency at the power distribution level can save tens of millions of kWh annually. From the roadside charger to the AI supercomputer, energy efficiency is now a material challenge — and nanocrystalline alloys are the answer.   4. Engineering for the Future: Why This Matters Power electronics is entering a new era — high frequency, high density, and high intelligence. But that progress depends on what’s inside the magnetic core.Without materials that can handle high flux, high frequency, and high temperature simultaneously, innovation stalls. Nanocrystalline alloys break that bottleneck.They bring: High magnetic flux density (1.2–1.6 T) Low losses at high frequency Thermal and magnetic stability across wide temperature ranges This unique balance between structure and performance makes nanocrystalline the material foundation of the next generation of power systems.   5. The Big Picture: Material Innovation Drives Energy Innovation From EV charging to AI datacenters, microgrids to renewable integration, the most advanced systems share one truth — they all rely on efficient magnetic materials. Nanocrystalline alloys are no longer a lab experiment.They’re being mass-produced, cost-optimized, and integrated into commercial products worldwide. Just as silicon enabled the digital revolution, nanocrystalline alloys are becoming the core material of the energy revolution.     Nanocrystalline cores redefine the boundaries of power electronics.They make systems smaller, cooler, smarter, and more efficient. In the transition toward electrification and intelligent power, this is the material that makes the impossible possible.
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  • Why Nanocrystalline Alloys Are the Core of Next-Generation Power Electronics
    Why Nanocrystalline Alloys Are the Core of Next-Generation Power Electronics
    Oct 28, 2025
    Nanocrystalline alloys deliver unmatched magnetic permeability, low core loss, and superior high-frequency stability—making them the ideal core material for solid-state transformers, EV chargers, and compact high-efficiency power systems.   Why This Material? — The Science Behind Nanocrystalline Alloys Among all soft magnetic materials, very few can simultaneously achieve low loss, high permeability, and stable high-frequency performance.Nanocrystalline alloys are the rare exception — a breakthrough material that bridges the gap between traditional silicon steel and amorphous alloys. Structurally, a nanocrystalline alloy consists of ultrafine crystalline grains (10–20 nm) embedded within an amorphous matrix.This hybrid structure combines the “no grain boundary, low eddy current” benefits of amorphous materials with the improved magnetic alignment of crystalline ones. The result is a magnetic material that maintains high permeability, low loss, and excellent thermal and frequency stability — the perfect foundation for modern power electronics and solid-state transformers (SSTs).   1. High Magnetic Permeability — The Key to Compact Efficiency Magnetic permeability defines how easily magnetic flux can pass through a material.Nanocrystalline alloys offer permeability in the range of 10⁵–10⁶, far exceeding that of silicon steel (≈10³–10⁴) and amorphous alloys (≈10⁴–10⁵). This enables transformers and inductors to shrink by 30–70% in volume and cut core weight by more than half, without sacrificing performance. Even more critically, nanocrystalline alloys retain high permeability under kilohertz-level frequencies,while silicon steel and amorphous cores experience sharp declines.That makes them the material of choice for high-frequency, high-efficiency SSTs, EV power modules, and data center converters.   2. Moderate Saturation Flux Density, Optimized for High-Frequency Stability Unlike amorphous alloys with higher Bs (≈1.5T) but poor high-frequency stability,nanocrystalline alloys offer a moderate Bs of ≈1.2T, balanced by ultra-low loss and superior permeability at operating frequencies of several kHz to tens of kHz. In high-power-density systems such as EV fast chargers or on-board DC/DC converters,where fast response and minimal heat buildup are essential,this balance allows higher efficiency, smaller size, and better thermal control. Simply put — amorphous may saturate higher, but nanocrystalline runs cooler and smarter.   3. Low Core Loss and High-Frequency Efficiency — The Foundation of Power Electronics The defining advantage of nanocrystalline alloys lies in their low total core loss across wide frequency ranges. High resistivity (110–130 μΩ·cm) suppresses eddy current loss; Tiny grain size (<20 nm) minimizes magnetic hysteresis and domain wall motion loss; Uniform internal stress ensures stability even under high switching frequencies. As a result, nanocrystalline cores deliver minimal power loss even at 10–50 kHz,making them the cornerstone for solid-state transformers and compact power converters that must operate efficiently under continuous high-frequency switching.   4. Thermal Stability and Reliability — Designed for Real-World Conditions Nanocrystalline alloys maintain magnetic performance consistently across -40°C to 150°C,ensuring reliability in both freezing northern climates and tropical heat. Their low loss and higher thermal conductivity reduce temperature rise within the magnetic core,simplifying cooling design and improving long-term system stability. For next-generation SSTs and EV power modules that must operate continuously,this translates directly into greater reliability and longer service life.   5. From Innovation to Industrial Scale — The Maturity Advantage Recent advances in ribbon casting, heat treatment, and coating technology have transformed nanocrystalline alloys from a lab innovation into a mass-produced industrial material.With mature Fe-Si-B-Cu-Nb alloy systems and large-scale production lines,China now leads in global capacity and application development, bringing down costs and enhancing consistency. Today, nanocrystalline ribbons are already used in solid-state transformers, EV fast chargers, UPS systems, and renewable power converters — validating their industrial readiness.   6. A Material for Its Time — The Energy Transition Catalyst Every phase of the energy transition is defined by a breakthrough material: The grid era belonged to silicon steel. The energy-saving transformer era belonged to amorphous alloys. The high-frequency, power-electronics era belongs to nanocrystalline alloys. With global surges in EVs, AI data centers, renewable energy, and high-efficiency charging,nanocrystalline materials are no longer an upgrade — they’re a necessity.   Nanocrystalline alloys are not just “better materials.”They are the enabling foundation of tomorrow’s power electronics ecosystem. Refer to our blog
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