A high permeability core plays a vital role in magnetic component performance. High permeability allows magnetic flux to pass through the core material with less resistance, leading to lower losses and better efficiency. MK Magnetics, Inc. produces advanced high permeability magnetic core solutions for industries that require precise performance, long service life, and consistent quality.

High Permeability Core Materials

MK Magnetics works with a range of high permeability core materials to meet varied electrical and mechanical requirements:

• Amorphous metals such as Metglas® 2605HB1M offer extremely low core loss, high resistivity, and thin laminations that reduce eddy current loss.
• Nanocrystalline alloys such as FINEMET® provide permeability from 500 to 100,000, high saturation induction near 1.2 T, and excellent stability across wide temperature ranges.
• Cobalt-based amorphous, with a flux density of 0.57T, with permeability up to 100,000. Near-zero magnetostriction and easily coercive.

The selection of high permeability magnetic core material depends on operating frequency, size requirements, loss limitations, and cost considerations.

Performance Advantages

A well-engineered high permeability core delivers several benefits:

• Reduced size and weight due to higher magnetic flux density.
• Improved efficiency in transformers and inductors through reduced hysteresis and eddy current losses.
• Excellent performance across frequencies from DC to 3MHz+.
• Consistent magnetic properties over a broad temperature range.
• Mechanical durability with compressive strength and hardness.

Applications

High permeability core materials support a wide range of applications:

• Power transformers – Distribution, medium-frequency, and renewable energy systems. These cores improve magnetic efficiency, reduce core losses, and enable smaller, lighter designs for modern grid and inverter-based systems.
• Electric motors – High-efficiency industrial motors and electric vehicle stators. Nanocrystalline materials minimize eddy current losses and enhance torque density, supporting the push for compact, energy-efficient motor solutions.
• Inductors and chokes – Common mode chokes, differential mode chokes, and PFC inductors. Their superior magnetic stability and low loss over wide frequency ranges ensure reliable EMI suppression and power conditioning performance.
• Wireless charging systems – Compact, thin-profile designs with high flux handling. High-permeability cores enable efficient power transfer at high frequencies, improving charging speed and alignment tolerance.
• Precision current transformers – Meeting stringent ANSI/IEC accuracy requirements. These materials provide exceptional linearity and thermal stability, ensuring accurate current measurement under varying load and temperature conditions.

Comparing Technologies

Amorphous cores offer low loss and high resistivity, making them suitable for power applications. Nanocrystalline cores provide higher permeability and frequency range for advanced filtering and signal applications. Cobalt based amorphous cores serve well in energy storage and high-power conversion. Compared to ferrites, these materials deliver higher flux density, lower loss, and better thermal stability.

MK Magnetics’ Capabilities

MK Magnetics has the engineering knowledge and manufacturing capacity to produce high permeability magnetic core solutions for both prototype and production volumes. Capabilities include custom shaping, gapping, and insulation methods, as well as performance testing for permeability, saturation induction, and core loss. Each core is processed with precision to match customer specifications.

Research continues into high-induction nanocrystalline alloys exceeding 1.8 T, with multiple cut configurations to exhibit low loss, as well as rapid annealing processes for faster production and new applications in electric vehicles and high-frequency power conversion. These advances aim to increase performance and reduce costs for end users.

Contact MK Magnetics

MK Magnetics provides engineering assistance, material selection guidance, and manufacturing expertise for projects requiring a high permeability core. Contact us today to discuss requirements and learn how MK Magnetics can supply the right high permeability magnetic core for your application.