Ultra-thin electrical steel is a thin-gauge electrical steel used in magnetic components where reducing magnetic losses and achieving compact designs are important.
Available in very thin gauges, it is suited to applications that operate at higher frequencies and require efficient magnetic performance. Its applications include transformers, reactors, inductors and precision power systems, making it relevant to a broad range of electrical and electronic applications.
This article explores why the demand for ultra-thin electrical steel is growing, how its properties affect magnetic performance, where it can be applied, and what designers should consider when evaluating it for their applications.
Why Are Magnetic Components Becoming Smaller and More Efficient?
The growing demand for higher efficiency, greater power density and smaller form factors is changing how magnetic components are designed. This shift is particularly relevant across electric power, renewable energy, industrial equipment and other applications where efficiency and space are increasingly important.
Higher Efficiency
Reducing energy losses is becoming increasingly important as electrical systems demand better overall performance.
Higher Power Density
Designers are looking to achieve more output from smaller magnetic components, particularly in compact power-conversion systems.
Smaller Footprint
Space constraints are driving the development of smaller transformers, reactors, inductors and other magnetic components.
Higher Operating Frequencies
Higher-frequency operation can support more compact magnetic designs, while also making control of magnetic losses increasingly important.
These changing requirements have increased the importance of the magnetic core and the material used to build it, creating greater interest in thinner electrical-steel solutions.
What Are the Benefits of Ultra-Thin Electrical Steel, and When Should You Consider It?
The thickness of electrical steel plays an important role in magnetic performance. Ultra-thin electrical steel is available in significantly thinner gauges than conventional electrical steel, with the supplied product material covering 0.04 – 0.10 mm for grain-oriented (GO) steel and 0.05 – 0.15 mm for non-grain-oriented (NGO) steel.
Its relevance becomes clearer when the design demands a combination of low magnetic losses, higher operating frequencies and compact dimensions.
Lower Core Losses
Reducing the thickness of the electrical steel helps suppress eddy-current losses, which can contribute to lower core or iron losses in magnetic components. This becomes particularly relevant as operating frequency increases.
Compact Magnetic Designs
Ultra-thin electrical steel can support the development of smaller magnetic components where size and power density are important design considerations. The supplied material specifically connects these characteristics with the miniaturisation of iron cores, reactors, motors and other magnetic components.
Higher-Frequency Operation
The supplied product information positions ultra-thin electrical steel for higher-frequency applications, with a stated operating range of 400 Hz to 40 kHz.
When Should You Consider It?
Ultra-thin electrical steel becomes particularly relevant when an application has demanding requirements around:
- Operating frequency
- Core loss
- Component size
- Power density
- Thermal performance
- Magnetic efficiency
The right material, however, depends on the requirements of the individual magnetic component. Factors such as frequency, magnetic performance, thickness, core geometry and the choice between GO and NGO material should be evaluated together rather than in isolation.
How Does Ultra-Thin Electrical Steel Reduce Magnetic Losses?
One of the key reasons for using thinner electrical steel is its effect on eddy-current losses.
When a magnetic core is subjected to an alternating magnetic field, electrical currents are induced within the steel. These circulating currents produce energy losses and heat. As the operating frequency increases, controlling these losses becomes increasingly important.
Reducing the thickness of the electrical steel limits the path available for these circulating currents, helping to suppress eddy-current losses. This is why thinner electrical steel becomes particularly relevant for higher-frequency magnetic applications.
Thickness and Eddy-Current Loss
In simplified terms:
Thicker electrical steel → greater eddy-current effects
Thinner electrical steel → reduced eddy-current effects
This relationship is one of the key engineering principles behind ultra-thin electrical steel.
Why Frequency Matters
As operating frequency rises, magnetic losses become increasingly important to the overall performance of a component. A material designed to control these losses can therefore become an important consideration in applications where higher-frequency operation and compact design are required.
For this reason, ultra-thin electrical steel can be relevant to high-frequency transformers, reactors, inductors and other magnetic components where controlling core losses is an important part of the design.
Where Is Ultra-Thin Electrical Steel Used, and How Does It Influence Magnetic Component Design?
The value of ultra-thin electrical steel becomes clearer when viewed through the applications it can support. Its combination of reduced magnetic losses, higher-frequency capability and compact form factors makes it relevant to several types of magnetic components.
High-Frequency Transformers
Ultra-thin electrical steel can be considered for transformers operating at higher frequencies, including applications such as EV chargers, renewable-energy inverters, DC transformer power systems and medical power supplies.
In these applications, controlling core losses can contribute to better efficiency while supporting more compact transformer designs.
Reactors and Line Chokes
Reactors and line chokes used in solar inverters, variable-frequency drives and industrial drives can also benefit from magnetic materials suited to higher-frequency operation.
For these components, considerations such as efficiency, thermal behaviour and power density can influence material selection.
High-Efficiency Inductors
Ultra-thin electrical steel is also relevant to inductors used in DC-DC converters, battery energy-storage systems and EV power electronics.
Here, the objective can be to achieve the required magnetic performance while keeping losses and component size under control.
Precision Power Supplies
In medical equipment, industrial automation and telecom power supplies, magnetic components often need to balance efficiency, thermal performance and compactness. Ultra-thin electrical steel can be considered where these requirements align with the characteristics of the material.
Across these applications, material selection is ultimately tied to the requirements of the finished component. Operating frequency, core losses, power density, thermal constraints, core geometry and overall component size all influence how a magnetic core should be designed.
Benaka’s Magnetic Component & Transformer Manufacturing Capability
Selecting the right magnetic-core material is only one part of developing a high-performance component. The final result also depends on the core configuration, windings, insulation, mechanical construction and the ability to manufacture the component to the required specifications.
Benaka Electronics brings these considerations together through its manufacturing capabilities across transformers, laminations, toroidal cores and related magnetic components.
Toroidal Cores & Transformers
Benaka manufactures toroidal cores and toroidal transformers for applications where compact design and efficient magnetic performance are important. Ultra-thin electrical steel can offer a relevant pathway for translating material advantages into more compact magnetic components, while customised core and transformer solutions can be developed around the specific electrical, dimensional and performance requirements of each application.
Customisation and Prototyping
For OEMs and product-development teams, magnetic components often need to meet specific electrical, thermal, mechanical and dimensional requirements. Benaka provides customised transformer solutions and prototyping capabilities to support these requirements.
This broader manufacturing capability is important because the material is only an input. The objective is ultimately to develop a magnetic component that performs reliably within the requirements of the end application.
Ultra-Thin Electrical Steel Available Through Benaka
To support the growing demand for compact and high-frequency magnetic components, Benaka is making customised ultra-thin electrical steel products available in India across multiple grades and formats.
The current offering includes:
GT-050
GT-080
GT-100
These grades are available in formats suited to different manufacturing requirements, including:
Available as a wide variety of Cores, Cut Cores, Gapped Cores, C Cores and many more.
Customised solutions for applications with specific dimensional or manufacturing requirements.
The availability of these options allows ultra-thin electrical steel to be considered not simply as a material choice, but as part of a broader magnetic-component design and manufacturing requirement.
Looking for a Magnetic Component for Your Application?
Selecting the right material is only the starting point. The performance of the final transformer, reactor, inductor or other magnetic component depends on how the material is integrated into the overall design.
If you are developing a magnetic component, the right solution depends on factors such as:
Application
What will the component be used for, and what operating conditions will it experience?
Electrical Requirements
Input and output voltage, power rating and operating frequency are key parameters in defining the component.
Size and Thermal Constraints
Physical dimensions, heat generation and installation requirements can influence the core and overall component design.
Production Requirements
Prototype development, required quantity, manufacturing format and customisation requirements also need to be considered.
With the right combination of material, core design and component engineering, ultra-thin electrical steel can play an important role in developing compact and efficient magnetic components.
Looking for a transformer, reactor, inductor or other magnetic component designed around your application? Talk to Benaka Electronics about your requirements.
Frequently Asked Questions
What is ultra-thin electrical steel?
Ultra-thin electrical steel is thin-gauge electrical steel used in magnetic components where controlling magnetic losses and achieving compact designs are important. The supplied product material covers GO thicknesses of 0.04–0.10 mm and NGO thicknesses of 0.05–0.15 mm.
What are the benefits of ultra-thin electrical steel?
Its key benefits include reduced eddy-current and core losses, suitability for higher-frequency applications, and support for more compact magnetic-component designs.
Where is ultra-thin electrical steel used?
It can be used in applications including high-frequency transformers, reactors and line chokes, high-efficiency inductors, and precision power supplies.
Can ultra-thin electrical steel be used in transformers?
Yes. The supplied application material specifically identifies high-frequency transformers for areas such as EV chargers, renewable-energy inverters, DC transformer power systems and medical power supplies.
Can it be used in reactors and inductors?
Yes. The supplied material identifies reactors and line chokes for applications such as solar inverters, VFDs and industrial drives, and inductors for DC-DC converters, battery energy storage and EV power electronics.
How does electrical-steel thickness affect core loss?
Reducing the thickness of the steel helps suppress eddy-current losses. This becomes particularly important as operating frequency increases.
What should be considered when selecting a magnetic-core material?
The selection should consider factors such as operating frequency, core loss, magnetic requirements, component size, thermal performance, core geometry and the specific requirements of the application.
What ultra-thin electrical steel options are available through Benaka?
Benaka’s new offering includes GT-050, GT-080 and GT-100, with availability in slit coils, laminations and customised solutions.
Talk to Benaka About Your Magnetic Component Requirement
The right magnetic material is ultimately determined by the requirements of the finished component. Whether the application involves a transformer, reactor, inductor or another magnetic component, factors such as operating frequency, power, core losses, dimensions and thermal requirements need to work together.
Benaka Electronics can support the development and manufacture of customised magnetic components based on application-specific requirements.
Planning a new magnetic component or looking to improve an existing design? Share your requirements with Benaka Electronics.