high saturation material for round rod

[BrianE22]

I'm looking at having to design a custom relay with not a lot of space for magnetics. I have space for a long coil and am looking to drive it with as much flux density as possible. For production, I'm guessing that a powder metal part is the way to go. For prototyping, what would be a good choice for about a 3/8 diameter armature round? I'll be turning part of it down and am o.k. with having to anneal it afterwords.

 

[EdStainless]

Max B at what field level?
It is tough to beat a low carbon steel like 1002 if the filed is low.
If the initial perm is not an issue then using 1020 will work just as well.
PM tends to have lower B because the density is less.


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Plymouth Tube

 

[dgallup]

PM is not the way to go for high flux density as Ed said. Pure iron is good except for low resistivity, may not be important if you are not trying to work at high frequency. If you want the highest possible flux density you need a high H field and iron-cobalt. There are several grades available from Cartech & VACUUMSCHMELZE. You won't like the price.

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[BrianE22]

Thanks guys. A high permeability would be nice also, but high saturation limit is more important. I think I have enough height available to get a long coil and a high number of amp-turns.

It will be a DC voltage on the coil. I have a request in to Cartech for suggested materials. I'll take a look at VACUUMSCHMELZE.

 

[EdStainless]

If the core is long you may be able to get away with making the upper 2/3 from steel and the bottom 1/3 from FeCo. That might help save money if you need to make a bunch of these. I have seen pole tips brazed on, and that cycle used for post machining stress relief.

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Plymouth Tube