Magnetic materials selection for static inverter and converter transformers

A program to study magnetic materials is described for use in spacecraft transformers used in static inverters, converters, and transformer-rectifier supplies. Different magnetic alloys best suited for high-frequency and high-efficiency applications were comparatively investigated together with an investigation of each alloy's inherent characteristics. The materials evaluated were the magnetic alloys: (1) 50% Ni, 50% Fe; (2) 79% Ni, 17% Fe, 4% Mo; (3) 48% Ni, 52% Fe; (4) 78% Ni, 17% Fe, 5% Mo; and (5) 3% Si, 97% Fe. Investigations led to the design of a transformer with a very low residual flux. Tests were performed to determine the dc and ac magnetic properties at 2400 Hz using square-wave excitation. These tests were performed on uncut cores, which were then cut for comparison of the gapped and ungapped magnetic properties. When the data of many transformers in many configurations were compiled the optimum transformer was found to be that with the lowest residual flux and a small amount of air gap in the magnetic material. The data obtained from these tests are described, and the potential uses for the materials are discussed.