Sendust Core for Power Inductor

Iron silicon aluminum magnetic core, material composition: 85% iron, 6% aluminum, 9% silicon; Permeability from 26 to 125;It is mainly used in power inductors, AC inductors, output inductors, line filters, power factor correction circuits and other switching power supplies, sometimes replacing air gap ferrite as transformer core.

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Comprising 85% iron (Fe), 9% silicon (Si) & 6% aluminum (Al), Sendust is an alloy powder material widely used in magnetics applications. It’s alternatively called as Kool Mu by Magnetics. It features itself with a low loss, relatively high saturation flux density (10,500 Gauss), close to zero magnetostriction as well as a very stable performance at high termperature, or say, no thermal aging.


What are the advantages of sendust core ?

1.Significantly lower core losses than Iron Powder for a relatively small price premium.

2.Low cost energy storage.

3.High energy storage per unit volume.

4.Temperature stable (under 4% variation from -15˚C to 125˚C).

5.Near zero magnetostriction, meaning very quiet when operating with audible frequency range noise or line current.

6.Performs better than Iron Powder where significant ripple may contribute to heat rise.


The application of powder core includes the following:

1.Energy storage filter inductors used in switch-mode power supplies.

2.In-Line noise filters where large AC voltage is needed without core saturation.

3.Line Filters (These can be smaller in size and require less turns than those using ferrite cores).

4.PFC (power factor correction) circuits (Due to high flux density and low core losses).

5.Unidirectional drive applications such as line output (flyback) transformers and pulse transformers.



Sendust core are formed by adding a certain amount of glass forming agent to the molten metal, and rapidly quenching and casting using a narrow ceramic nozzle under high temperature melting conditions. Amorphous alloys have the similar characteristics of glass structure, which not only make them have excellent mechanical properties, physical properties and chemical properties, but more importantly, the new technology of producing amorphous alloys using this rapid quenching method is less than the cold-rolled silicon steel sheet process. 6 to 8 processes can save energy consumption by 60% to 80%, which is an energy-saving, time-saving and efficient metallurgical method. Moreover, the amorphous alloy has low coercivity and high magnetic permeability, and its core loss is significantly lower than that of oriented cold-rolled silicon steel sheet, and its no-load loss can be reduced by about 75%. Therefore, the use of amorphous alloys instead of silicon steel sheets to manufacture transformer cores is one of the main means to save energy and reduce consumption in today’s power grid equipment.

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