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We developed Fe/FeSiAl soft magnetic powder cores (SMCs) for realizing the miniaturization and high efficiency of an electromagnetic conversion coil in the high-frequency range (∼20 kHz). We found that Fe/FeSiAl SMCs can be formed with a higher density under higher compaction pressure than pure-iron SMCs. These SMCs delivered a saturation magnetic flux density of 1.7 T and iron loss (W1/20k) of 158 kW/m3. The proposed SMCs exhibited similar excellent characteristics even in block shapes, which are closer to the product shapes.

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