High-Permeability Magnetic Composites With Cement, Asphalt, and Epoxy Binders for Enhanced Performance Across Diverse Applications

As the global demand for energy transition and transport decarbonization intensifies, the development of advanced magnetizable materials becomes crucial for supporting large-scale applications. This study presents the optimization of MAGMENT composites, which are produced using recycled ferrite aggregates combined with binders, such as cement, asphalt, or epoxy. These composites are engineered to achieve high magnetic permeability and low core losses, key characteristics for efficient energy systems. Our results demonstrate that by fine-tuning the aggregate size and volume fraction, permeability can be significantly enhanced, with volume fractions above 65% showing the most promise. Although cement workability imposes a 73% limit, the performance of these composites still surpasses industry benchmarks, notably the KH-HT 60µ from KEDA, by refining the particle size distribution. Adjusting the nominal maximum aggregate size from 4.5 to 19 mm changes permeability from 40 to 180. The superior magnetic performance of the MC60 grade, particularly its minimal core losses, underscores its potential as a leading material in the market. These advancements are for applications in wireless charging, both static and dynamic, and in high-power transmission systems, addressing critical needs in sustainable transport and energy infrastructure. The use of recycled materials further aligns with the global push for environmentally responsible technologies.