Coating possibilities for magnetic switches

High average power magnetic pulse compression systems are now being considered for use in several applications such as the High Power Radiation Source (HiPoRS) project. Such systems will require high reliability magnetic switches (saturable inductors) that are very efficient and have long lifetimes. One of the weakest components in magnetic switches is their interlaminar insulation. Considerations related to dielectric breakdown, thermal management of compact designs, and economical approaches for achieving these needs must be addressed. Various dielectric insulation and coating materials have been applied to Metglas foil in an attempt to solve the complex technical and practical problems associated with large magnetic switch structures. This work reports various needs, studies, results, and proposals in selecting and evaluating continuous coating approaches for magnetic foil. Techniques such as electrophoretic polymer deposition and surface chemical oxidation are discussed. We also propose continuous photofabrication processes for applying dielectric ribs or spacers to the foil which permit circulation of dielectric liquids for cooling during repetitive operation.