reduce core loss in power electronics

• Why Engineers Are Switching from Ferrite to Nanocrystalline Magnetic Cores

  

  Aug 01, 2025

  Engineers in EV, solar, and high-frequency power electronics are replacing ferrite cores—not because nanocrystalline sounds cool, but because it saves time, space, and real money.   What Are Nanocrystalline Magnetic Cores? Nanocrystalline cores are made from iron-based alloys (Fe-Si-Nb-Cu-B) processed through rapid solidification and annealing, resulting in ultra-fine microstructures. This gives them magnetic properties far superior to traditional ferrite.   The Real Shift: What Engineers Are Trying to Solve Design engineers today face: Increasing EMI compliance demands Smaller device footprints Higher switching frequencies (10kHz–30MHz) Rising cost pressure + shorter go-to-market cycles In that context, ferrite cores—despite being cheap—often fail to deliver.   Key Advantages of Nanocrystalline Cores 📌 30% Lower Core Losses Lower loss = lower heat = higher efficiency.Less need for thermal management = lower BOM cost. 📌 Saturation Flux Density ≥ 1.2 Tesla That's 2–3x more than ferrites (~0.4T).Your system can tolerate current surges without magnetic saturation or damage. 📌 Broadband EMI Suppression Works effectively from 1kHz to 30MHz, unlike MnZn or NiZn ferrite with narrow frequency bands.➡️ Result: EMI passes on first try, saving you days of debugging. 📌 Size & Weight Reduction Nanocrystalline cores can achieve the same performance as ferrite with up to 45% smaller volume and 47% lower weight—key for EV and compact PSU designs. 📌 Superior Thermal Stability Performance remains consistent from –40°C to 140°C.Curie temperature >570°C = stable under continuous thermal load.   Ferrite vs. Nanocrystalline – A Real Business Case Feature Nanocrystalline Ferrite Bs (T) ≥ 1.2T ~0.4T Core Loss Low High EMI Band 1kHz–30MHz Narrow Temp Stability Excellent Moderate Size / Weight Small / Light Bulky Long-Term Cost Lower Higher (rework, EMI fails)   💡 What looks cheaper per piece may cost you more in testing, rework, and compliance.   Application Scenarios Where Nanocrystalline Excels EV onboard DC-DC converters Solar inverters (MPPT + PFC stage) High-frequency industrial SMPS EMC filters and common-mode chokes Smart meter & high-speed data power supplies   Customer Feedback: Engineering That Pays Off “We solved an EMI issue in 2 hours that took 3 days with ferrite.” – Automotive client “Your cores helped us reduce power supply temp by 8°C. That’s a big win.” – German inverter customer “We passed CE compliance in one shot. No retesting.” – OEM, Vietnam    Better Magnetics = Smarter Business Engineers are not switching just for performance—they’re switching because: ✅ They save time✅ They save space✅ They reduce redesign cycles✅ They improve thermal performance✅ They pass EMI faster In power design, every second and every degree matters. If you want your next product to be smaller, cooler, and faster to certify—start from the core.   👨‍🔧 Author:   Julia YimInternational Marketing ManagerDongguan JH Amorphous Co., Ltd.📧 julia@amorphousoem.com | 🌐 www.amorphousoem.com  

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