Aeronautic transformers have the basic requirements of power, voltage level and no load losses, but also have specific constraints in terms of volume, weight, audible noise level and cost. If only volume and weight reduction are taken as design parameter, the use of FeCo alloys is the straightforward solution: FeCo alloys have higher saturation levels than FeSi alloys and therefore allow the working point of the transformer to be shifted to higher polarisation levels, resulting in lower magnetic core cross sections and hence lower transformer volumes. Also, FeCo has high electrical resistivity which minimises eddy current losses, so high efficiency can be reached. On the other hand FeSi alloys clearly have lower saturation polarisation, but they can be designed for high resistivity and the use of different production methods can lead to quite different permeability levels and quite different anisotropies of the magnetic performances in the rolling plane, so e.g. a Grain Oriented FeSi already allows higher exploitation polarisations than Non Oriented FeSi electrical steels but only in the rolling direction. The same R&D strategy is driven with the development of Goss textured alloys with low cobalt content. Since ArcelorMittal offers such a wide range in FeCo and FeSi chemistries and production methods, there is a clear quantification needed to define the pros and cons of each solution. This paper provides such quantification and helps making an optimal material choice in terms of transformer performance, dimensions and cost, in the very precise case of E-I shaped and punched 3-phase transformer cores. A last important point within the material choice context is the audible noise the transformer makes, which of course impacts the comfort of pilots and passengers in air traffic. A qualitative approach is used to clarify this factor, based on magnetostriction elements.


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