Selective oxidation of rare metal oxide insulation layers on particle substrates for optimizing the performance of FeSiCr-based soft magnetic composites

Huang, Huaqin; Wang, Jian; Cui, Zhenghao; Gao, Zihan; Huang, Zengqi; Wu, Zhaoyang

doi:10.1016/j.matdes.2023.111984

Cited by 17 publications

(4 citation statements)

References 46 publications

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“…The new economic situation has demanded the development of miniaturized, lightweight, energy-saving soft magnetic composite devices that operate at high frequency and high temperatures. Accordingly, soft magnetic composite materials with excellent comprehensive performance, especially those that improve the permeability and reduce the core loss, has become an important research direction in the magnetic materials field [4][5][6].…”

Section: Introductionmentioning

confidence: 99%

“…To achieve the above goals, researchers have explored various methods: doping with a highly permeable magnetic fine powder to enhance the magnetic coupling between magnetic particles, developing magnetic insulating media that enhance the ferromagnetic filling factor, and optimizing the heat-treatment process of soft magnetic composites to improve the crystal structure and stress state of the magnetic phase [5]. Other promising strategies are the preparation of an insulation layer [3] based on hot-pressing sintering [6] and heat-treatment processes that induce an interfacial solid-phase reaction. The performances of SMCs can be optimized by designing the surface reaction and optimizing the composition of the insulation layer.…”

Section: Introductionmentioning

confidence: 99%

“…The performances of SMCs can be optimized by designing the surface reaction and optimizing the composition of the insulation layer. For example, Huang et al [6] found that during hot-pressing sintering, the selective oxidation of Si by CeO 2 forms a CeO 2 •SiO 2 composite insulation layer on the surface of Fe-Si-Cr soft magnetic powder in situ. This composite insulation layer with high resistivity can effectively reduce the eddy-current loss of SMCs at midrange and high frequencies.…”

Section: Introductionmentioning

confidence: 99%

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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: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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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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“…Soft magnetic composites (SMCs) are formed by applying organic, inorganic, or hybrid organic-inorganic coatings to soft magnetic metal powders, followed by compression molding; this process is advantageous in controlling eddy current loss by forming an insulating layer between powders [1][2][3][4][5][6]. When a current is generated in the core, heat is generated, and the eddy current loss can be prevented by this insulating layer, thereby reducing core loss.…”

Section: Introductionmentioning

confidence: 99%

Improved Soft Magnetic Properties in FeNi@MgO Composites by Sol-Gel-Based Surface Coating and High-Temperature Heat Treatment

Park,

Kim,

Lee

et al. 2023

Metals

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In this study, we utilized MgO as an insulating buffer layer to enhance the thermal stability and soft magnetic properties of Fe-Ni soft magnetic composites (SMCs) and investigated the effect of high-temperature heat treatment on those soft magnetic properties. By employing the sol-gel process, a uniform MgO insulating layer with a thickness of 600 nm was coated onto Fe-Ni magnetic powder. Subsequently, high-density SMCs were fabricated through high-pressure compaction molding. The MgO layer remained intact up to 800 °C, leading to the FeNi@MgO@MK SMCs exhibiting enhanced permeability and reduced hysteresis loss due to grain enlargement and elimination of defects, such as dislocation stacking. Notably, the dynamic loss increase after high-temperature heat treatment was significantly regulated compared to the case of the uncoated counterpart. The results underscore the potential to improve the thermal stability and soft magnetic properties of MgO-coated Fe-Ni SMCs, rendering them suitable for various electromagnetic applications.

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Preparation of composite insulating layer using Ca(OH)2 coating and thermal decomposition to optimise the performance of FeSiAl-based soft magnetic composites

Liu,

Wu,

et al. 2024

J Mater Sci: Mater Electron

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Selective oxidation of rare metal oxide insulation layers on particle substrates for optimizing the performance of FeSiCr-based soft magnetic composites

Cited by 17 publications

References 46 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

Improved Soft Magnetic Properties in FeNi@MgO Composites by Sol-Gel-Based Surface Coating and High-Temperature Heat Treatment

Preparation of composite insulating layer using Ca(OH)2 coating and thermal decomposition to optimise the performance of FeSiAl-based soft magnetic composites

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