We propose to develop a novel nano-laminated Fe magnetic core material. With our proprietary technique, we have developed a process to create Fe sheets of hundred nanometers thick. By coating these Fe sheets with a thin insulating layer and subsequent consolidation, we can achieve nano-laminated soft magnetic Fe cores, which is a nano-scale version of the conventional laminated silicon steel cores. This innovation makes it possible to form and preserve the nanometer sheet structures during the process. The process greatly simplifies the manufacture procedures and reduces the cost. The net-shape capability further reduces the cost. The materials have low weight and are anticipated to have good mechanical properties. More importantly, it is likely to achieve high magnetic flux density over a wide frequency from dc to MHz range, surpassing any current commercial materials. The proposal objective is the feasibility demonstration of fabricating nano-laminated Fe cores with high flux density close to 1.9T, low weight, low cost, and good mechanical properties. Specifically, we will (1) determine the experimental conditions to form nano-laminates; (2) optimize the structure to achieve good magnetic properties; and (3) achieve dense compacted samples with magnetic and mechanical properties similar to those of M-19 silicon steel
