There is an increasing demand for miniaturizing magnetic components such as inductors and transformers in power converters. This demand is driven by the decreasing size of electronic products and by the potential savings which might be achieved by integrating such components on integrated circuits. Magnetic components are typically the largest components by size and dissipate the most energy. Increasing the frequency at which converters operate can decrease the size of these components and increase their power handling capacity per unit area. However conventional soft magnetic materials are not optimized for operation at high frequencies where they exhibit undesirable characteristics such as high core loss. The primary goal of the research is to design and synthesize novel multi-layered nano-granular soft magnetic materials that can be used for high-frequency switched mode power converters. Properly characterizing the losses in the magnetic material from the context of it being used as a magnetic core is paramount in understanding the next steps needed to improve the material and the potential application in devices. Furthermore, to enable development of on-chip power converters, the synthesis methodology must be compatible with CMOS processes. In this thesis, several soft magnetic materials were synthesized using reactive sputtering. The synthesis process was thoroughly documented to ensure that the process can be easily repeated. A framework is also detailed that can be used for the thorough analysis of losses in a magnetic core and the framework is utilized to analyze the magnetic materials design. Two materials which are heavily emphasized in my work are Co-Zr-O and Ni-Fe-Zr-O. The basic characteristics of Co-Zr-O have been investigated in prior work and my work provides more detailed information on its performance under different operating and synthesis conditions. Ni-Fe-Zr-O is a newly designed granular material and its magnetic and loss characteristics are presented. After characterizing suitable materials, thick films were prepared as cores for inductors. Results of the performance of thick films are also presented.

The book aims to provide comprehensive and practical guidance on magnetism and magnetic materials. It involves four parts, focusing on fundamental magnetism, hard magnetic materials, soft magnetic materials and other functional magnetic materials. Part I highlights the ubiquity of magnetism and the close relationships between magnetic materials and our daily life. Perspectives on magnetism from Engineering and Physics are provided to introduce the two unit systems, followed by the origin and categories of magnetisms. An introduction of important parameters during magnetization and magnetic measurement techniques are then provided to lay a solid foundation for the readers for better understandings of the design and development of different magnetic materials. Important magnetic materials are then introduced in the subsequent parts, delivering an overview of design principles, production technologies, research developments and real-world applications. For instance, rare-earth-free and rare-earth-based hard magnetic materials as well as soft magnetic materials such as Fe-based alloys, composites and ferrites are discussed. Other functional magnetic materials span a wide range, involving smart materials with magneto-X effects, together with magnetic materials for applications including electromagnetic wave absorption, biomedicine and catalysis, etc. For these magnetic materials, more emphasis is placed on the latest advances and interdisciplinary perspectives.

A multidisciplinary team of Carnegie Mellon University (CMU) researchers with substantial support from the public and private sectors was assembled to develop new materials with improved magnetic and mechanical properties at high temperature. The group worked on the refinement of existing soft bulk materials while conducting research on novel nanocrystalline magnets in parallel. The team also studied existing and new high temperature permanent magnetic materials for use in aircraft engine applications. A vigorous search for new magnetic materials, both hard and soft, was conducted. Prototypes for bulk soft magnets were Fe-Co alloys. The effects of alloy grain size, structural order, orientation, and texture were studied to maximize induction and permeability, and minimize hysteretic and eddy current losses at elevated temperatures. Investigation of nanocrystalline materials for soft magnetic applications proceeded on two fronts: plasma synthesis of magnetic nanoparticles followed by the use of compaction techniques to form dense magnets, and the nanocrystallization of amorphous precursors to produce exchange coupled magnetic nanocrystals. The first effort has led to the synthesis of metallic nanoparticles, of new core shell structures, and nanocrystalline ferrites. The second effort has led to the discovery of a new nanocrystalline soft magnetic material called HITPERM on which work continues to explore its use in power electronic applications. For hard magnetic materials capable of operating at up to 400 degrees, the team investigated Co-containing 2:17, 1:12, and 3:29-based permanent magnet materials. They investigated the fundamental properties of these alloy systems as well as processing protocols for engineering optimal microstructures for hard magnetic properties. Co-containing 3:29 phase magnets have extended the temperature range of these materials. Rapid solidification was used to tailor microstructure and harness anisotropy.

Magnetic Components for Power Electronics concerns the important considerations necessary in the choice of the optimum magnetic component for power electronic applications. These include the topology of the converter circuit, the core material, shape, size and others such as cost and potential component suppliers. These are all important for the design engineer due to the emergence of new materials, changes in supplier management and the examples of several component choices. Suppliers using this volume will also understand the needs of designers. Highlights include: Emphasis on recently introduced new ferrite materials, such as those operating at megahertz frequencies and under higher DC drive conditions; Discussion of amorphous and nanocrystalline metal materials; New technologies such as resonance converters, power factors correction (PFC) and soft switching; Catalog information from over 40 magnetic component suppliers; Examples of methods of component choice for ferrites, amorphous nanocrystalline materials; Information on suppliers management changes such as those occurring at Siemens, Philips, Thomson and Allied-Signal; Attention to the increasingly important concerns about EMI. This book should be especially helpful for power electronic circuit designers, technical executives, and material science engineers involved with power electronic components.

This book addresses the biologically controlled synthesis of magnetic materials, and its applications in bio-inspired design and synthesis. It highlights several key aspects of biologically produced magnetic materials – (i) organisms that biologically synthesize and utilize magnetic materials; (ii) formation mechanisms; (iii) how these biological formation routes yield various phases and morphologies; and (iv) the resultant magnetic and structural properties – and describes diverse bio-inspired approaches to utilizing magnetic materials in applications ranging from semiconductor to health industries. In addition, the book discusses the recent industrial use of magnetic materials to develop scalable technologies that encompass protein displays, drug-delivery, biophysical separations, and medical diagnostics, as well as outlining future next-generation applications. As such, it offers valuable insights for all scientists interested in using multidisciplinary fields to overcome current obstacles, and in gaining multifaceted expertise in magnetic materials bionanotechnology.

Chemical Solution Synthesis for Materials Design and Thin Film Device Applications presents current research on wet chemical techniques for thin-film based devices. Sections cover the quality of thin films, types of common films used in devices, various thermodynamic properties, thin film patterning, device configuration and applications. As a whole, these topics create a roadmap for developing new materials and incorporating the results in device fabrication. This book is suitable for graduate, undergraduate, doctoral students, and researchers looking for quick guidance on material synthesis and device fabrication through wet chemical routes. Provides the different wet chemical routes for materials synthesis, along with the most relevant thin film structured materials for device applications Discusses patterning and solution processing of inorganic thin films, along with solvent-based processing techniques Includes an overview of key processes and methods in thin film synthesis, processing and device fabrication, such as nucleation, lithography and solution processing