Effects of Coating Characteristics of One-Step Aerosol Synthesized–Silica-Coated FeNi Nanostructured Particles on Powder Core Properties for Electronic Machine Development

Abstract

Nanostructured particles with a core−shell structure have been highlighted in recent developments in various fields including electronic machinery applications. Applying nonagglomerated nanoscaled-silica-coated soft-magnetic particles into powder core inductors (PCIs), power converters in electronic machines, promises efficiency improvement. In this study, nanostructuring silica-coated FeNi (FeNi@SiO 2 ) particles was conducted via an aerosol method by introducing the SiO 2 (0.4 nm) from hexamethyldisiloxane to the FeNi particles. The effect of varying the supplied amounts of FeNi (as the core) and SiO 2 (as the shell) materials on the core−shell structure and electrical properties of a powder core was investigated. The results revealed that controlling the FeNi core number (N FeNi ) played a critical role in determining the coating characteristics. Applying a higher N FeNi yielded superior coating properties, characterized by decreased shell inhomogeneity and pristine silica nanoparticles due to heterogeneous nucleation. Notably, a higher level of shell inhomogeneity and the presence of silica nanoparticles caused increased eddy current loss and decreased the breakdown voltage in the powder core. This is the first study to elucidate the correlation between the structure of FeNi@SiO 2 particles and the electrical properties of a powder core. This study provides insights into the factors influencing nanoscaled-coating characteristics and powder core properties, which are crucial for advancing electronic components.