Rigid high magnetic permeability materials

[artis]

Hi, for lower frequencies most electrical devices use laminated electric steel , like transformers and motors. But this makes the core made up of individual metal sheets and in older transformers taking the core apart sometimes results in the individual sheets falling apart.

Is there any material with similar or better magnetic properties than the laminated steel which would be rigid, similar to a ferrite core where the whole core (whatever shape) is a one piece material?
I ask this because I'm making a core for an experimental device and the geometry of it is such that laminated steel can't be applied as the flux path would be faced not with the "thin" parts of the laminations but with the flat ones, also the laminations couldn't be kept together easily.

 

[Baluncore]

Consider an iron powder or ferrite core. Cores are usually made from metal powder and a binder, pressed, then fired in a kiln to become a ceramic or glass.

You can cast your own cores with crushed ferrite or iron powder and epoxy glue. Make the mold from modelling clay or silicon rubber.
Alternatively, break or cut up ferrite core material and glue bits back together to make the shape you need. Use ferrite that meets your frequency specification.

The magnetic field passes through the insulating binder to reach the magnetic material. The magnetic particles must be smaller for higher frequencies.