Amorphous alloy transformer coils

As key components in modern power transmission and distribution systems, the innovation of amorphous alloy transformer coils’ design and manufacturing technology is of great significance for improving energy efficiency, reducing losses and promoting green and sustainable development.

Characteristics of amorphous alloy material 

Amorphous alloy, also known as metallic glass or disordered metal alloy, is an alloy material with a long-range disordered structure obtained by rapid solidification technology (such as melt spinning). Compared with traditional crystalline alloys, amorphous alloys have the following significant characteristics:

High saturation magnetic induction intensity: The saturation magnetic induction intensity of amorphous alloys is close to or slightly higher than that of silicon steel sheets, which means that the volume and weight of the transformer core can be reduced at the same magnetic flux density.

Extremely low iron loss: Especially at low and medium frequencies, the iron loss of amorphous alloys is much lower than that of traditional silicon steel sheets, which is crucial to reducing the no-load loss of transformers.

Good magnetic stability and temperature stability: The magnetic properties of amorphous alloys change less with temperature, which helps to maintain the stable operation of transformers under different environmental conditions.

Excellent corrosion resistance and processability: Amorphous alloys are not easy to rust and are easy to process into various shapes, providing more flexibility for coil design.

Performance advantages

The application of amorphous alloy transformer coils has brought significant performance improvements:

Significantly reduce no-load loss: Compared with traditional silicon steel sheet transformers, amorphous alloy transformers can reduce no-load loss by about 60%-80%, which is of great significance for reducing grid losses and improving energy efficiency.

Improve energy efficiency ratio: Due to reduced losses, amorphous alloy transformers have higher energy efficiency ratios under the same load conditions, which helps reduce carbon emissions and promote environmental protection.

Enhance grid stability: The low loss and high efficiency of amorphous alloy transformers help improve the voltage quality and stability of the grid and reduce harmonic pollution.

Manufacturing process

The manufacturing of amorphous alloy transformer coils involves multiple links, among which the key technologies include:

Precision cutting and forming of amorphous alloy strips: Use high-precision cutting equipment to cut amorphous alloy strips into the required shape. Then use special processes to improve its mechanical strength and processing performance.

Coil winding technology: Use automated winding equipment to ensure the accuracy and consistency of coil winding. For large coils, it may be necessary to wind in sections and then splice them.

Insulation and impregnation treatment: Select suitable insulation materials, perform multi-layer insulation treatment on the coil, and enhance the stability and durability of the insulation layer through the impregnation process.

Assembly and vacuum drying: Assemble the coil and other components (such as the core) into a transformer and perform vacuum drying to remove internal moisture and gas and improve electrical performance.

With the global emphasis on energy conservation, emission reduction and green energy development, the application prospects of amorphous alloy transformer coils are broad. Especially in high-energy consumption fields such as urban power grid transformation, new energy power generation, rail transportation, data centers, etc., amorphous alloy transformers will become one of the mainstream products in the future transformer market due to their significant energy-saving effects. At the same time, with the continuous advancement of material science, manufacturing processes and intelligent technology, the performance of amorphous alloy transformer coils will be further optimized and the cost will be further reduced, which provides possibilities for a wider range of application scenarios.