Enhanced magnetic and mechanical properties of gas atomized Fe-Si-Al soft magnetic composites through adhesive insulation

Shi, Xiaoyan; Chen, Xuyong; Wan, Kun; Zhang, Bowei; Duan, Pengtao; Zhang, Hua; Zeng, Xudong; Liu, Wei; Su, Hailin; Zou, Zhongqiu; Du, Youwei

doi:10.1016/j.jmmm.2021.168040

Cited by 30 publications

(4 citation statements)

References 27 publications

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“…The immersion layers produced on the magnetic powder were investigated, among others, in [5]. The aim of this study was to improve both the magnetic and mechanical properties of the SMC composite by producing an adhesive layer containing MgO and aluminium dihydrogen phosphate.…”

Section: Simulation Of Magnetic Properties Of Composites Based On Mag...mentioning

confidence: 99%

3D Printing of Composite Material for Electromechanical Energy Harvesters

et al. 2022

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In this paper, a novel, composite material is proposed based on ferromagnetic wires immersed in a polymer that is well suited for 3D printing. The magnetic properties of this material are examined using FEM and compared with the properties of a more traditional composite based on magnetic powder. For a 50% ferromagnetic volume in the material, the proposed composite has a 67% higher value of saturation magnetic flux density and 87% higher value of maximum permeability, compared with the powder-based material. The authors believe that the proposed material could be used in the manufacturing of small electromechanical devices such as energy harvesters, thus vastly widening the possible fields of application related to 3D printing techniques.

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Section: Simulation Of Magnetic Properties Of Composites Based On Mag...mentioning

confidence: 99%

3D Printing of Composite Material for Electromechanical Energy Harvesters

et al. 2022

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“…In recent years, organic insulators such as polyimide [5], silicone resin [6], and epoxy resin [7] have been widely utilized in industrial production owing to their favorable adhesion and extensibility properties; however, their poor thermal stability limits their practical applicability. To overcome the shortcomings of organic insulating layers when utilized in iron-based SMCs, researchers have used metal oxides (AO x ) such as MgO [8], ZrO 2 [9], MnO 2 [10], and Al 2 O 3 [11] as insulating layers given their high thermal stability and resistivity, which are strongly dependent on point defects [12][13][14]. For example, Wei et al [15] deposited MgO cladding on an Fe-Si-Al alloy powder, which resulted in a permeability of 74.49 and a loss of 414.76 mW/cm 3 at 50 kHz.…”

Section: Introductionmentioning

confidence: 99%

Effect of Various Metal Oxide Insulating Layers on the Magnetic Properties of Fe-Si-Cr Systems

Huang

et al. 2023

Coatings

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Iron-based soft magnetic composites (SMCs) are the key components of high-frequency electromagnetic systems. Selecting a suitable insulating oxide layer and ensuring the integrity and homogeneity of the heterogeneous core–shell structure of SMCs are essential for optimizing their magnetic properties. In this study, four types of SMCs—Fe-Si-Cr/ZrO2, Fe-Si-Cr/TiO2, Fe-Si-Cr/MgO, and Fe-Si-Cr/CaO—were prepared via ball milling, followed by hot-press sintering. The differences between the microscopic morphologies and magnetic fproperties of the Fe-Si-Cr/AOx SMCs prepared using four different metal oxides were investigated. ZrO2, TiO2, MgO, and CaO were successfully coated on the surface of the Fe-Si-Cr alloy powders through ball milling, forming a heterogeneous Fe-Si-Cr/AOx core–shell structure with the Fe-Si-Cr alloy powder as the core and the metal oxide as the shell. ZrO2 is relatively hard and less prone to breakage and refinement during ball milling, resulting in a lower degree of agglomeration on the surface of the composites and prevention of peeling and collapse during hot-press sintering. When ZrO2 was used as the insulation layer, the magnetic dilution effect was minimized, resulting in the highest resistivity (4.2 mΩ·cm), lowest total loss (580.8 kW/m3 for P10mt/100kHz), and lowest eddy current loss (470.0 kW/m3 for Pec 10mt/100kHz), while the permeability stabilized earlier at lower frequencies.

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“…A variety of methods for coating, such as the sol–gel method [ 10 ], the ball milling method [ 11 ], the bonding method [ 12 ], and the liquid phase method [ 13 ], have been used, all having their own advantages and disadvantages. But in most coating processes, it is very difficult to obtain an ideal coating, i.e., as thin as a mono-atom layer, fully dense, continuous and with a high electric resistance.…”

Section: Introductionmentioning

confidence: 99%

Low Core Losses of Fe-Based Soft Magnetic Composites with an Zn-O-Si Insulating Layer Obtained by Coupling Synergistic Photodecomposition

Wang

Zheng

et al. 2022

Materials

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The major method used to reduce the magnetic loss of soft magnetic composites (SMCs) is to coat the magnetic powder with an insulating layer, but the permeability is usually sacrificed in the process. In order to achieve a better balance between low losses and high permeability, a novel photodecomposition method was used in this study to create a ZnO insulating layer. The effect of the concentration of diethyl zinc on the formation of a ZnO insulating film by photodecomposition was studied. The ZnO film was best formed with a diethyl zinc n-hexane solution at a concentration of around 0.40 mol/L. Combined with conventional coupling treatment processes, a thin and dense insulating layer was coated on the surface of iron powder in situ. Treating the iron powder before coating by photodecomposition led to a synergistic effect, significantly reduced core loss, and the effective permeability only decreased slightly. An iron-based soft magnetic composite with a loss value of 124 kW/m3 and an effective permeability of 107 was obtained at the frequency of 100 kHz and a magnetic field intensity of 20 mT.

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Enhanced magnetic and mechanical properties of gas atomized Fe-Si-Al soft magnetic composites through adhesive insulation

Cited by 30 publications

References 27 publications

3D Printing of Composite Material for Electromechanical Energy Harvesters

3D Printing of Composite Material for Electromechanical Energy Harvesters

Effect of Various Metal Oxide Insulating Layers on the Magnetic Properties of Fe-Si-Cr Systems

Low Core Losses of Fe-Based Soft Magnetic Composites with an Zn-O-Si Insulating Layer Obtained by Coupling Synergistic Photodecomposition

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