Soft Magnetic Composite Resources

What is Soft Magnetic Composite?

In recent decades, designs in automotive and other industries have demanded better magnetic materials. Since the 1990s, soft magnetic composite (SMC) has filled that gap -- but only for engineering teams aware of what it can bring to an electric application.

Soft magnetic composites offer 3-D shape-making and other design possibilities that simply didn’t exist before. With the right SMC your technology can:

  • Run faster
  • Consume far less energy
  • Become more compact & dense
  • Achieve high permeability
  • Use higher frequencies
  • Experience lower core/eddy loss

Are you completely in the dark on soft magnetic composites? All brushed up on the basics but need a little more research? Or somewhere in between? Keep reading to learn what makes SMC so important to parts in motor and other applications.



Fran Hanejko is an industry-leading expert who happens to work with Horizon as our Senior Advanced Materials Engineer. Fran has decades of experience in the powder metal industry, including managing customer applications for Hoeganaes Corp., the world’s leader in metal powder development and production. He graduated from Drexel University in 1974 with a master’s degree in materials engineering.

Contact Fran with your questions by filling out the form below. 


Level 2: Intermediate 

Application of High-Performance Materials -- Electromagnetic Products

This paper discusses the use of high-performance materials for D/C applications as well as the use of insulated powders for high- and low-frequency applications. Alloys of iron and silicon are highlighted.

Source: Fran Hanejko, George Ellis, Timothy Hale

Material Cost Savings in Powder Metal Transfer Case Sprockets & Sun Gears

For years, powder metal nickel steel sprockets have been in use in the SUV transfer case market. The heat-treated powder metal provides high strength and wear resistance for a demanding application. Due to rising raw material prices several years ago, researchers found a replacement material with comparable properties at a competitive price. Click the link above to see the analysis.

Source: Fran Hanejko, Marc Legault, & David Pendrak

New SMCs for Electromagnetic Applications With Improved Mechanical Properties 

The chance to move from 2-D to 3-D design of electrical machines is possible thanks to soft Magnetic composites. These iron-based powders are insulated and pressed to realize shapes otherwise impossible with traditional lamination sheets. This paper presents recent progress in mixing SMC iron powders and phenolic resin, in different weight percentages and mold pressures. The goal? Compromising between magnetic and mechanical qualities.

Source: Luca Ferrarisa, Emir Pošković, & Fausto Franchini

1P? 3P? 5P? What Can These Powder Metal Processes Do For Your Numbers? 

Powder metal does more than you might think -- if you’ve got the right material. Knowing the strengths and subtleties of each material process can make your product stand out in a competitive market. Three emerging material processes you should know about ASAP are the 1P, 3P, and 5P soft magnetic composites. Here’s how each material will bestow certain qualities on your application.

Source: Horizon Technology

This New Generation of Direct-Drive Electric Machines Will Power Our Future 

Manufacturers of wind turbines and electric machines always had to find a balance between using generators with low-weight, low-reliability systems and using heavy, high-efficiency systems. A new generation of motors and generators based on axial flux technology combines the best of both worlds. This blog post describes the difference between axial and radial flux technologies.

Source: Magnax 

Advances in Powder Metallurgy Soft Magnetic Composite Materials 

Today, more than 90% of powder metal products are used in the transportation industry. Development of new materials such as magnetic materials is expected to meet the “faster-smaller-denser” demands of the automotive industry. This paper investigates the correlation between compaction parameters, inner structure, magnetic qualities, and mechanical properties.

Source:  Archives of Metallurgy and Materials