About the project

Development of innovative, environmentally friendly soft magnetic cores by powder metallurgy technology.

Project Summary

Materials for more efficient electrification

Magnetic cores are found in almost every electrical device – from electric motors and generators to transformers and chargers. Their quality directly determines how much energy is converted into useful work and how much is lost as heat.

The GreenMagCore project is developing new Soft Magnetic Composites (SMC) using powder metallurgy. The aim is to create materials with lower energy losses, higher efficiency and better performance, produced by a technology that consumes less energy and makes almost full use of raw materials.

Iron powder attracted by a magnet

The Project in Numbers

  • Project duration
    36 months1 September 2026 – 31 August 2029
  • Acronym (project code)
    GreenMagCorePK.1.1.13.0002
  • Project lead
    Dr. Franjo Tuđman Defense and Security University
  • Industrial partner
    ORQA d.o.o.
  • Technology transfer partner
    Center for Technology Transfer Ltd.
  • Total project value
    EUR 728,342.58
  • Of which co-financed
    EUR 625,425.46
  • Co-financed by
    European Union
  • Fund
    European Regional Development Fund
  • Programme
    Competitiveness and Cohesion Programme 2021–2027
  • Intermediate Body 1
    Ministry of Science, Education and Youth (MZOM)
  • Intermediate Body 2
    Croatian Agency for SMEs, Innovations and Investments (HAMAG-BICRO)
Objectives

The Challenge and Our Solution

The Challenge

Soft magnetic materials are indispensable in transformers, electric motors, generators and inductors. Soft magnetic composite (SMC) cores consist of ferromagnetic particles, most often iron, coated with a thin insulating layer that reduces eddy currents and magnetic losses. Compared with conventional electrical steel laminations, they have lower losses at high frequencies, greater thermal resistance and make better use of magnetic flux, which makes them key to electric mobility and high-efficiency motors.

However, existing SMC materials have weak points: the insulating layers are damaged during pressing, porosity occurs, and the microstructure degrades at elevated temperatures.

Our Solution

GreenMagCore is developing new formulations of iron-based powder materials with insulating additives (oxides, nitrides and nanoparticles) and optimising their consolidation processes – pressing and heat treatment. The goal is to achieve low porosity, high density and a stable microstructure, and therefore better magnetic and mechanical properties.

Powder metallurgy is also the more environmentally friendly choice: it consumes less energy, operates at lower temperatures, generates minimal material waste and allows almost complete recycling of input raw materials.

Project Objectives

Innovative SMC formulations

Develop innovative SMC material formulations using powder metallurgy.

Optimal consolidation processes

Investigate optimal consolidation processes (pressing and heat treatment).

Microstructure and properties

Link the microstructure and properties of the materials through characterisation of their physical, mechanical and magnetic properties.

Industrial validation

Validate the developed materials against the requirements of the industrial partner.

Research group and laboratory

Establish a research group and laboratory infrastructure for further development at higher technology readiness levels.

Intellectual property and cooperation

Lay the groundwork for intellectual property protection and continued cooperation between the academic and private sectors.

Why Does It Matter?

Energy efficiency

Lower core losses mean more efficient electric motors, transformers and electronic components, and therefore lower electricity consumption and lower CO₂ emissions.

European independence

The new materials do not depend on rare earth elements; instead, they are based on iron and oxide powders available on the European market. In this way, the project contributes to the goals of the Critical Raw Materials Act (CRMA) and to reducing dependence on imports from third countries.

Filling the gap

Until now, Croatia has had no research group systematically studying the relationship between the microstructure, process technology and magnetic properties of these materials. GreenMagCore brings together an interdisciplinary team of experts in materials science, mechanical engineering, electrical engineering and chemistry.

The path to market

The industrial partner is involved from day one – defining requirements and testing materials under operating conditions – which steers the research towards real-world application from the very start.

Activities

Project Activities

  1. 1

    Industrial Research

    The core activity of the project: from setting up the laboratory and developing the methodology, through material selection, consolidation and characterisation, to validating the materials under industrial conditions and preparing scientific publications.

    More information

    The research follows an iterative cycle: material formulation → consolidation → characterisation → industrial validation → formulation improvement. Each round of testing yields new insights into the relationship between process, microstructure and the functional properties of the materials.

    Research Phases

    1. 1
      State of the art and industrial requirements

      Analysis of scientific literature, patent databases, the market and competitors. Orqa engineers define the operational requirements, technical constraints and target performance of the materials.

    2. 2
      Setting up the laboratory

      A Materials Characterisation Laboratory is being set up at the Dr. Franjo Tuđman Defense and Security University, equipped for analysing microstructure as well as mechanical and physical properties.

    3. 3
      Powder selection and mixture formulation

      Iron-based starting powders and insulating additives (oxides, nitrides, nanoparticles) are selected, and mixtures are prepared for the first consolidation phase. The starting powders are analysed by optical and electron microscopy (morphology, microstructure, particle size).

    4. 4
      First consolidation phase

      Isostatic pressing is used to produce samples (so-called green bodies) which are tested for density, porosity and homogeneity. The results are used to select the best formulations.

    5. 5
      Final consolidation and heat treatment

      The best formulations undergo warm pressing in a protective atmosphere followed by heat treatment to optimise the microstructure. This stage is carried out in cooperation with external research laboratories, which will also perform independent testing of the magnetic properties.

    6. 6
      Characterisation of properties

      Detailed testing of the magnetic, physical and mechanical properties of the developed materials.

    7. 7
      Industrial validation

      Orqa engineers and technicians test the materials under simulated operating conditions and provide feedback for further optimisation.

    Research Infrastructure

    In addition to the new Materials Characterisation Laboratory at SOIS FT, the project uses the research infrastructure of the Faculty of Mechanical Engineering and Naval Architecture, University of Zagreb, and its Powder Metallurgy Laboratory, accessible through CTT, as well as the expertise of external specialised research institutes. The equipment procured within the project will remain permanently at the University and will be used for further research, teaching and services to other research and industrial organisations.

    Potential Applications

    • Electric motors and generators
    • Transformers and inductive components
    • Electric vehicles and e-mobility
    • Unmanned aerial vehicles
    • Energy systems
    • High-reliability electronics
    months 1–36
  2. 2

    Activities Aimed at Continuing Research and Cooperation Between Academia and Industry

    Developing a Long-Term Cooperation Strategy for SOIS FT – Orqa – CTT, strategic planning workshops and preparing project proposals to continue research at higher technology readiness levels.

    months 20–36
  3. 3

    Intellectual Property Assessment and Protection

    Prior art search and freedom-to-operate assessment, market and competitor analysis, development of an intellectual property protection strategy and a technology transfer strategy and filing of an application for protection. This also includes establishing an institutional framework for intellectual property management at the University.

    months 1–36
  4. 4

    Horizontal Activities

    Workshops on equality, accessibility and sustainable resource management, a “Women in STEM” workshop and green laboratory measures.

    months 1–36
  5. 5

    Dissemination of Research Results and Networking

    Participation in national and international conferences and trade fairs, a round table on cooperation between science and industry, and the project’s closing conference.

    months 6–36
  6. 6

    Project Management

    Coordination of the Consortium, implementation planning and monitoring, financial management, reporting and risk management.

    months 1–36
  7. 7

    Promotion and Visibility

    Project visual identity, website and social media, promotional materials, media relations, and the opening conference and public events.

    months 1–36
Funding

Co-funded by the European Union

Co-funded by the European Union

The project Development of innovative, environmentally friendly soft magnetic cores by powder metallurgy technology – GreenMagCore (PK.1.1.13.0002) is co-funded under the call “Collaborative Scientific Research” (PK.1.1.13), European Regional Development Fund, Competitiveness and Cohesion Programme 2021–2027. The content of this website is the sole responsibility of the Dr. Franjo Tuđman Defense and Security University.

Total project value
EUR 728,342.58
Of which co-financed (EU)
EUR 625,425.46
Intermediate body 1
Ministry of Science, Education and Youth (MZOM)
Intermediate body 2
HAMAG-BICRO