Influence of sintering temperature on heterogeneous-interface structural evolution and magnetic properties of Fe–Si soft magnetic powder cores

Wang, Rui; He, Yihai; Kong, Hui; Wang, Jian; Wu, Zhaoyang; Wang, Haichuan

doi:10.1016/j.ceramint.2022.06.250

Cited by 23 publications

(6 citation statements)

References 36 publications

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“…However, after doping with low-resistivity CIPs, the elimination of pores made the energy obtained by the external electric field carriers easily overcome the well barrier and pass from the interface region into the transition region. Therefore, the number density and mobility of carriers improved, the blocking effect of the insulation layer on the conductive network formed by the soft magnetic powder weakened, and the resistivity lowered [18]. At the highest doping rate (20 wt%), the CIPs particles aggregated and the irregularly distributed high-resistivity pores were reformed, thereby increasing the resistivity.…”

Section: Resultsmentioning

confidence: 99%

Investigating the Effect of Carbonyl Iron Powder Doping on the Microstructure and Magnetic Properties of Soft Magnetic Composites

Liu,

Wang,

et al. 2024

Magnetochemistry

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This study proposes the thermal decomposition of salt compounds and doping of carbonyl iron powders (CIPs) to optimize the preparation of an insulating layer through the solid-phase interface reaction. First, (Fe–Si–Cr + CIPs)/ZnSO4 composite powders were synthesized using the hydrothermal method and (Fe–Si–Cr + CIPs)/ZnO·SiO2·Cr2O3 SMCs with a ZnO·SiO2·Cr2O3 composite insulation layer were prepared through heat treatment and cold pressing. The effect of the CIP doping content on the microstructure and magnetic properties of the (Fe–Si–Cr + CIPs)/ZnO·SiO2·Cr2O3 SMCs were then investigated. During the heat treatment, ZnSO4 decomposed into solid ZnO and gaseous SO2 and O2. The O2 drives the solid-phase reaction, prompting the migration of nonmagnetic Si and Cr atoms from the interior of the Fe–Si–Cr soft magnetic powder to the surface insulation layer, finally forming the ZnO·SiO2·Cr2O3 insulation layer. The doped CIPs also show good plasticity during the coating process, combining with the coating layer to fill the internal pores of SMCs. Moreover, as the particles are small with a high surface area, they increase the number of reaction sites for ZnSO4 decomposition and facilitate the growth of the composite insulation layer, promoting its uniform distribution on the surfaces of the soft magnetic powders and CIPs. The lattice mismatch between the insulation layer and soft magnetic powder is reduced while the magnetic-phase content is increased, allowing the effective doping of CIPs sin the insulation layer. The magnetic properties of SMCs can be precisely regulated by changing the doping amount of CIPs. Unlike other insulating layer–preparation strategies based on the interfacial solid-phase reaction, the proposed method exploits the high plasticity and specific surface area of CIPs and removes the lattice mismatch between the insulation layer and soft magnetic powder.

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Section: Resultsmentioning

confidence: 99%

Investigating the Effect of Carbonyl Iron Powder Doping on the Microstructure and Magnetic Properties of Soft Magnetic Composites

Liu,

Wang,

et al. 2024

Magnetochemistry

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“…To highlight the prominent comprehensive soft magnetic properties of the ASMC with CSAS, previously reported data including M s , µ e (100 kHz) and P cv (0.1 T, 100 kHz) of the ASMCs prepared by the atomized powders were summarized [11,12,17,18,[47][48][49][50][51], and compared with the current study in figures 3(d) and (e). It can be seen that µ e of most ASMCs is less than 60 combined with a limited M s lower than 150 emu g −1 which is not favorably comparable to some of the traditional metallic magnetic powders such as the FeSi powder [16]. To further enhance the M s of the ASMCs, crystalline FeCo powder with extremely high M s is often added as another magnetic phase [47,50].…”

Section: Improved Comprehensive Soft Magnetic Propertiesmentioning

confidence: 99%

“…However, since the cooling rate of atomization, especially the gas atomization, is well below that of conventional melt spinning method, the content of ferromagnetic elements in the ASMCs is limited to a lower level than that of the amorphous ribbons [14]. Consequently, the saturation magnetizations (M s ) of the ASMCs are far below those of the typical amorphous ribbons such as METGLASS [15] and letting alone Fe-Si crystalline SMCs [16], which has become a main drawback restricting the miniaturization of modern electronics. Apart from the M s , effective permeability (µ e ) and P cv are also two important soft magnetic properties of SMCs.…”

Section: Introductionmentioning

confidence: 99%

Critical state-induced emergence of superior magnetic performances in an iron-based amorphous soft magnetic composite

Shao,

Bai,

et al. 2024

Mater. Futures

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Soft magnetic composites (SMCs) play a pivotal role in the development of high-frequency, miniaturization and complex forming of modern electronics. However, they usually suffer from a trade-off between high magnetization and good magnetic softness (high permeability and low core loss). In this work, utilizing the order modulation strategy, a critical state in a FeSiBCCr amorphous soft magnetic composite (ASMC), consisting of massive crystal-like orders (CLOs, ~1 nm in size) with the feature of α-Fe, is designed. This critical-state structure endows the amorphous powder with the enhanced ferromagnetic exchange interactions and the optimized magnetic domains with uniform orientation and fewer micro-vortex dots. Superior comprehensive soft magnetic properties at high frequency emerge in the ASMC, such as a high saturation magnetization (Ms) of 170 emu/g and effective permeability (μe) of 65 combined with a core loss (Pcv) as low as 70 mW/cm3 (0.01 T, 1 MHz). This study provides a new strategy for the development of high-frequency ASMCs, possessing suitable comprehensive soft magnetic performance to match the requirements of the modern magnetic devices used in the third-generation semiconductors and new energy fields.

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“…The sintering temperature was increased from 25 • C to 900 • C within 10 min and maintained at this level for 10 min at a pressure of 14 MPa. After sintering, the SMCs were annealed at 650 • C for 120 min [22]. The final dimensions of the prepared Fe-Si-Cr/AO x SMCs were 5 mm in height with outer and inner diameters of 30 and 20 mm, respectively.…”

Section: Materials Preparationmentioning

confidence: 99%

“…Choi et al [17] prepared Al 2 O 3 insulating layers of varying thicknesses on the surface of Fe-Si-Cr alloy powders using the sol-gel method, thereby fabricating a composite with an effective permeability of 33.9 and a loss of 252 mW/cm 3 at 50 mT and 100 kHz. Although previous studies [18][19][20][21] have demonstrated that metal oxides are promising candidates for use as insulating layers in the production of Fe-based SMCs, recent studies have predominantly focused on developing new metal oxide insulating layers and improving the properties of Fe-based SMCs [22,23].…”

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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Influence of sintering temperature on heterogeneous-interface structural evolution and magnetic properties of Fe–Si soft magnetic powder cores

Cited by 23 publications

References 36 publications

Investigating the Effect of Carbonyl Iron Powder Doping on the Microstructure and Magnetic Properties of Soft Magnetic Composites

Investigating the Effect of Carbonyl Iron Powder Doping on the Microstructure and Magnetic Properties of Soft Magnetic Composites

Critical state-induced emergence of superior magnetic performances in an iron-based amorphous soft magnetic composite

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

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