Performance improvement of Fe-6.5Si soft magnetic composites with hybrid phosphate-silica insulation coatings

Fe-6.5Si soft magnetic composites(SMCs)with hybrid phosphate-silica insulation coatings have been designed to improve their comprehensive property via chemical coating combining sol-gel method in this work.The microstructure and magnetic performance of the Fe-6.5Si SMCs with hybrid phosphate-silica insulation coatings were investigated.The hybrid phosphate-silica coatings with high heat resistance and high withstand pressure,formed on the surface of the Fe-6.5Si ferromagnetic powders,were found stable in the composites.Compared with Fe-6.5Si SMCs coated by single phosphate or single silica,Fe-6.5Si SMCs with hybrid phosphate-silica show much higher permeability and lower core loss.The work provides a new way to optimize the magnetic performance of soft magnetic composites.

Sodium Nitrate Passivation as a Novel Insulation Technology for Soft Magnetic Composites

Sodium nitrate passivation has been developed as a new insulation technology for the production of FeSiAl soft magnetic composites (SMCs). In this work, the evolution of coating layers grown at different pH values is investigated involving analyses on their composition and microstructure. An insulation coating obtained using an acidic NaNO_(3) solution is found to contain Fe2O_(3), SiO_(2), Al2O_(3), and AlO(OH). The Fe2O_(3) transforms into Fe3O4 with weakened oxidizability of the NO_(3)– at an elevated pH, whereas an alkaline NaNO_(3) solution leads to the production of Al2O_(3), AlO(OH), and SiO_(2). Such growth is explained from both thermodynamic and kinetic perspectives and is correlated to the soft magnetic properties of the FeSiAl SMCs. Under tuned passivation conditions, optimal performance with an effective permeability of 97.2 and a core loss of 296.4 mW∙cm−3 is achieved at 50 kHz and 100 mT.

Preparation and characterization of carbonyl iron soft magnetic composites with magnesioferrite insulating coating layer

Spherical carbonyl iron(Fe)powders were coated with magnesioferrite(MgFe2O4)insulating coating layer and then mixed with epoxy-modified silicone resin(ESR).Soft magnetic composites(SMCs)were fabricated by compaction of the coated powders and annealing treatment.Transmission electron microscopy(TEM),scanning electron microscopy(SEM),energy dispersive spectroscopy(EDS),X-ray diffractometry(XRD)and X-ray photoelectron spectroscopy(XPS)revealed that the MgFe2O4 layer was coated on the surface of the iron powders.The magnetic properties of SMCs were determined using a vibrating sample magnetometer and an auto testing system for magnetic materials.The results showed that the SMCs prepared at 800 MPa and 550℃ exhibited a significant core loss of 167.5 W/kg at 100 kHz and 50 mT.

Hysteresis loss reduction in self-bias FeSi/SrFe_(12)O_(19)soft magnetic composites

The magnetic field provided by magnetized SrFe_(12)O_(19)particles in FeSi/SrFe_(12)O_(19)composites is used to replace the applied transverse magnetic field,which successfully reduces the magnetic loss of the composites with minor reduction of permeability.This magnetic loss reduction mainly comes from the decrease in hysteresis loss,while the eddy current loss is basically unaffected.The hysteresis loss reduction in magnetized composites is believed to be due to the decrease in domain wall displacement caused by the increase in the average magnetic domain size in a DC magnetic field.This is an effective method for reducing the magnetic loss of soft magnetic composites with wide application potential,and there is no problem of increasing the cost and the volume of the magnetic cores.

High-frequency magnetic properties and core loss of carbonyl iron composites with easy plane-like structures

To fully release the potential of wide bandgap(WBG)semiconductors and achieve high energy density and efficiency,a carbonyl iron soft magnetic composite(SMC)with an easy plane-like structure is prepared.Due to this structure,the permeability of the composite increases by 3 times(from 7.5 to 21.5)at 100 MHz compared with to the spherical carbonyl iron SMC,and the permeability changes little at frequencies below 100 MHz.In addition,the natural resonance frequency of the composite shifts to higher frequencies at 1.7 GHz.The total core losses of the composites at 10,20,and 30 m T are80.0,355.3,and 810.7 m W/cm^(3),respectively,at 500 k Hz.Compared with the spherical carbonyl iron SMC,the core loss at500 k Hz is reduced by more than 60%.Therefore,this kind of soft magnetic composite with an easy plane-like structure is a good candidate for unlocking the potential of WBG semiconductors and developing the next-generation power electronics.

Investigation of Thermal Losses in a Soft Magnetic Composite Using Multiphysics Modelling and Coupled Material Properties in an Induction Heating Cell

The complex interaction between material properties in an induction heating circuit was studied by multi physics simulation and by experimental verification in a full-scale laboratory heater. The work aims to illustrate the complexity of the system of interacting materials, but also to propose a method to verify properties of soft magnetic composite materials in an integrated system and to identify which properties are the most critical under different circumstances and load cases. Heat losses at different loads were primarily studied, from DC currents to AC currents at 15, 20 and 25 kHz, respectively. A FE model for magnetic simulation was correlated with a corresponding model for heat simulation. The numerical model, as well as the established input material data, could be verified through the experimental measurements. In this particular study, the current loss in the litz wire was the dominant heat source, thus making the thermal conductivity of the SMC the most important property in this material.

Effect of Fe Substitution on Magnetic Properties and Radar Wave Absorption of the Y_(2)Co_(17) Rare Earth Soft Magnetic Alloy

The rapid development of information technology leads a demand for high frequency soft magnetic materials with ex-ceptional radar wave absorption properties.A new magnetic material with superior radar wave absorption is explored in this paper.we explored the preparation of Y_(2)Co_(17)-xFex(x=0.0,1.0,2.0,3.0)alloy powders using yttrium oxide as a raw material by a low-cost and short preparation cycle reduction-diffusion process.The crystal structure,intrinsic magnetic properties,high frequency magnetism and radar wave absorption of Y_(2)Co_(17)-xFex(x=0.0,1.0,2.0,3.0)were investigated.These compounds have a perfect magnetic repair of Y_(2)Co_(17) and enable the improvement of the overall magnetic properties of Y_(2)Co_(17)-xFex(x=0.0,1.0,2.0,3.0)compounds.The Y_(2)Co_(17)-xFex/Polyurethane(PU)(x=0.0,1.0,2.0,3.0)absorbers were divided in detail using the zero-reflection mechanism.The results show that all Y_(2)Co_(17)-xFex/PU(x=0.0,1.0,2.0,3.0)absorbers have excellent absorption performance(reflection loss RL is less than-85 dB);in addition,Y_(2)Co_(15)Fe_(2)/PU absorbers and Y_(2)Co_(14)Fe_(3)/PU absorbers are superior candidates for S-band materials.In particular,the perfectly matched frequency fp of the modulated Y_(2)Co_(14)Fe_(3)/PU absorber is shifted to the L-band(1–2 GHz)where early warning radars are located.The Y_(2)Co_(14)Fe_(3)/PU absorber has an effective absorption bandwidth of 300 MHz(1.5–1.8 GHz)at a thickness of 5.230 mm.It can also absorb the full L-band at-4 dB,which has rarely been reported.

Effects of two silicone resin coatings on performance of FeSiAl magnetic powder cores

Two silicon resins with excellent thermal stability,JH1123 and JH7102,are used as the insulated agents and binders for the gas-atomized FeSiAl powder,and corresponding magnetic powder cores(MPCs)are fabricated.The insulation capability and application prospects of the two silicon resins are evaluated by comparing the magnetic properties of the coated powder and MPCs.The scanning electron microscopy,energy dispersive X-ray spectroscopy and Fourier transform infrared spectroscopy results show that uniform insulation layers are both formed on the powder surfaces.JH1123 has stronger binding ability,and the JH1123-coated powder exhibits severe agglomeration,with d50(average particle size)approximately twice that of the JH7102-coated powder.Both as-prepared MPCs exhibit outstanding soft magnetic properties.Wherein,the permeability of FeSiAl@JH1123 is up to 74.0,which is 35.5%higher than that of FeSiAl@JH7102 because JH1123 can further improve the density of the MPCs.As for FeSiAl@JH7102,it has better direct current bias and lower core loss of 716.9 mW cm^(−3) at 20 mT and 1000 kHz due to its lower coercivity and greater anti-magnetic saturation ability.A comprehensive comparison shows that FeSiAl@JH1123 is suitable for medium and high frequency applications,while FeSiAl@JH7102 is more suitable for high frequency applications.This indicates that the use of JH1123 and JH7102 silicon resins for binding and insulated coating not only simplifies the preparation process of MPCs,but also enables the controlled production of MPCs for different applications.

High-frequency magnetic properties of biphase Ce_(2)Fe_(17)N_(3)/α-Fe microflakes with easy-plane anisotropy

Soft magnetic composites(SMCs)are effective as magnetic powder cores in an inductor.Due to high saturation magnetization,large magnetocrystalline anisotropy and high operating frequency of M(metal)-RE(rear earth)soft magnetic composites,it is possible to miniaturize inductor cores by reducing total loss,especially eddy current loss and excess loss at high frequencies.In this article,the characteristics of Ce_(2)Fe_(17)N_(3)/α-Fe(CFN/F)loss per volume and effective permeability reaching a high frequency of 3 MHz are investigated.The biphase CFN/F composite exhibits a high permeability of 16 at 70 MHz,which is two times greater than that of pure Ce_(2)Fe_(17)N_(3)(CFN)powders.The total loss is as low as 545 mW/cm^(3)at 3 MHz and 6 mT.The direct current(DC)-bias properties have a percent of permeability exceeding 65% at H=7960 A/m.This phenomenon indicates that our material has a higher working frequency and lower core loss than other materials;the biphase CFN/F structure is a promising and efficient approach for developing the miniaturized radio frequency(RF)inductor core.

磷酸含量对FeSiCr@磷酸盐/硅酸钠软磁粉芯性能的影响

基于粉末冶金工艺制备FeSiCr@磷酸盐/硅酸钠软磁粉芯,采用扫描电镜(SEM)、X射线衍射(XRD)与盐雾等实验方法与损耗分离计算,探究不同磷酸含量(质量分数为0~1.5%)对FeSiCr复合粉芯软磁性能与耐蚀性的影响。研究结果表明,适度增加磷酸含量,可提高磁粉芯相对密度与直流偏置性能,并显著降低磁粉芯损耗。但过高的磷酸含量会降低绝缘层均匀性,增加磁畴壁运动的阻力,导致磁粉芯损耗增加与磁导率下降。此外,磁粉芯耐蚀性也随磷酸含量增加而下降。当磷酸质量分数为1.0%时,FeSiCr磁粉芯具备最优综合软磁性能,磁导率为38.3(100 kHz时),损耗为646.24 mW/cm^(3)(1 MHz与20 mT时)。

高磁导率软磁复合材料研究进展

近年来,随着电子产品的高频化、小型化、多元化发展,作为电子元器件重要原材料之一的软磁复合材料受到学术界和工业界的广泛关注,如何获得高磁导率、高饱和磁感应强度、低损耗、低矫顽力的软磁复合材料成为研究重点。本文总结了提高软磁复合材料磁导率的制备工艺现状,概述了不同的制备工艺对材料性能的影响,展望了软磁复合材料成型工艺的发展趋势和发展方向,以期为软磁复合材料的发展提供参考。

磷酸绝缘包覆对铁硅铝磁粉心的影响

以破碎铁硅铝合金粉为原料,通过调节磷酸用量和引入Zn2+对粉末进行化学绝缘包覆,制备了铁硅铝磁粉心。采用FESEM、XRD、同步热分析仪、B-H分析仪等检测设备,对粉体形貌、物相、热稳定性和磁粉心磁性能、电性能进行表征和检测。结果表明:Zn2+的引入能有效改善铁硅铝颗粒表面绝缘层形貌,形成的绝缘层由纳米级网状结晶磷酸盐组成,致密、均匀地分布在颗粒表面,在有效降低磁粉心功率损耗的同时,提升了磁导率。

温压温度对FeSiBC非晶磁粉芯压缩以及磁学性能的影响

高电阻率的无机氧化物纳米粒子被广泛用作软磁粉芯的绝缘包覆材料,以降低粉芯高频下的涡流损耗,提升器件的工作稳定性和能量利用效率。针对非磁性氧化物纳米粒子的存在会导致粉芯致密性和磁导率下降的问题,本文将温压工艺引入FeSiBC非晶磁粉芯的制备中,重点研究温压温度对FeSiBC非晶磁粉芯的成形性、磁学性能以及力学性能的影响。结果表明:温压温度为120℃时,软化的树脂能够有效填充进磁粉间的间隙,增强黏结效果,使粉芯具有最佳的压缩性和综合磁学性能。此时,原始和包覆粉芯的抗压强度分别为220.0和269.1 MPa,相较于室温压制粉芯分别提升了107.5%和47.8%;有效磁导率在100 kHz~10 MHz范围内分别稳定至20.8和18.7 H/m,相较于室温压制粉芯分别提升了20.9%和16.9%;1 MHz、0.05 T下的交流损耗分别为2693.5和2228.0 kW/m^(3),相较于室温压制粉芯分别下降了13.9%和21.3%。本工作通过优化温压工艺参数,提升磁粉芯的应用频率和能量利用效率,为制备性能优良的FeSiBC磁粉芯提供指导。

面向高频应用的Fe-Si-Al软磁粉芯制备工艺改进及性能表征

为了提升Fe-Si-Al软磁粉芯的抗饱和性能,解决高频下产生较大的磁损耗等问题,本研究利用Al3+水解法制备了氧化铝包覆小粒径Fe-Si-Al粉末制备软磁粉芯工艺,探究了铝源液中氧化铝含量和成型压强对软磁粉芯高频磁性能的影响。运用扫描电子显微镜对经不同氧化铝含量的铝源液水解物包覆处理的Fe-Si-Al粉末表面形貌进行了表征,借助傅里叶红外光谱仪对包覆层成分进行分析。结果表明随着氧化铝含量增加,由包覆层引起的结构退磁场逐渐增大,软磁粉芯的有效磁导率减小,抗磁饱和性能改善;成型压强主要通过影响粉芯内部的气隙率和包覆层的质量来影响粉芯磁性能,压强越大,气隙率越小,有效磁导率越大,但压强过大会破坏粉末表面包覆层,恶化磁性能。经测定氧化铝含量为2.0 wt%、成型压强为1 860 MPa时获得的软磁粉芯的有效磁导率约为60;外加直流磁场强为8 000 A/m时,粉芯的有效磁导率百分比(%μe)高达63.84%;200 kHz/50 mT条件下磁损耗为235.7 mW/cm^(3)。

一体成型电感用软磁粉末应用现状及发展趋势

随着电子器件小型化、片式化、高频化、高功率密度化发展,一体成型电感以其感量高、耐大电流、漏磁小、尺寸多样化等优点获得了广泛应用。首先概括介绍了一体成型电感磁心用软磁粉末的分类与特性,包括羰基铁、铁硅铬、非晶/纳米晶,然后介绍了粉末制备工艺、特点、绝缘包覆,及其对电感特性的影响。最后对一体成型电感磁心用软磁粉末的未来发展进行了展望。

粉末粒径及其配比对FeSiAl软磁复合材料性能的影响

对气雾化法制备的球形FeSiAl粉末进行粒径优选及配比,通过耐高温复合磷酸盐和硅树脂对其进行有机-无机双绝缘包覆,然后将其制备成软磁复合材料。系统研究了粉末粒径及配比对材料密度、高频功率损耗、磁导率和直流偏置等性能的影响。结果表明,软磁复合材料的密度、磁导率和功率损耗随粉末粒径的减小而降低,直流偏置特性随粒径的减小而改善。当平均粒径为6.28μm时,1 MHz下的有效磁导率为59.21,在Bm=30 mT,f=1 MHz的条件下损耗为335.57 kW/m^(3),在100 Oe磁场下的磁导率百分比为64.42%。通过将平均粒径为18.76μm和12.72μm的两组粉末进行粒度配比,发现随着细磁粉含量的增大,密度与磁导率均先增大后减小,同时在Bm=30 mT,f=1 MHz高频条件下的损耗由624.50 kW/m^(3)减小至575.76 kW/m^(3)。

Controllable SiO2 coating layer of FeSiBPNb amorphous powder cores with excellent soft magnetic properties

Amorphous powder cores based on spherical （Fe0.76Si0.09B0.1P0.05）99Nb1 amorphous powder and their SiO2 layer prepared by in situ coating insulation process were investigated in detAll. These cores were characterized by scanning electron microscopy and X-ray diffraction analyses, and the results revealed that the surface layer of the amorphous powder was composed of SiO2 with uniform surface coverage. The thickness of the SiO2 insulating layer could be controlled by adjusting the tetraethyl orthosilicate （TEOS） content. By cold-pressing with epoxy resin under a pressure of 1800 MPa, a ring powder core with an outer diameter of 20.3 ram, inner diameter of 12.7 mm, and height of 5.3 mm was prepared. The FeSiBPNb composite core showed its best properties when the TEOS content was 2 mL/g （the volume of TEOS for each gram of （Fe0.76Si0.09B0.1P0.05）99Nb1 amorphous powder, mL/g）, which showed good relative permeability in the high-frequency range of up to 10 MHz and a low core loss of 320 W/kg under the maximum magnetic flux density of 0.1 T and frequency of 100 kHz.

谐波激励下软磁复合材料磁芯损耗的有限元计算

为精确、快速地计算谐波激励软磁复合材料(SMC)的磁芯损耗,将有限元模型法与数学模型修正系数法相结合,分别在介观和宏观尺度下建立SMC单个颗粒及实际环形样件的三维有限元模型。基于有限元模型计算谐波激励多变量条件下(如谐波的含量、相位和阶次等)SMC的磁芯损耗,与环形样件法的试验测量结果对比。结果表明:计算与测量结果一致,满足工程精度要求。与磁芯损耗的纯数学模型计算方法相比,有限元模型不仅能考虑磁滞回线局部小回环对SMC磁芯损耗的影响,且考虑集肤效应对涡流损耗的影响。测试发现,SMC的磁芯损耗随谐波含量和阶数增加而增大,受谐波相位的影响很小。

铁基软磁复合材料的SiO_(2)包覆研究进展

软磁复合材料在诸多领域有着重要的应用,随着技术的发展,对软磁复合材料的性能要求也在不断提高中。为了满足在高频率和高功率工况下的应用需求,需要开发低损耗、高磁导率的软磁复合材料。SiO_(2)作为绝缘包覆介质具有高电阻率和高热稳定性,能够通过多种方法包覆在磁粉颗粒上,因此在新型软磁复合材料开发领域得到广泛的应用。总结了溶胶凝胶法、化学液相沉积法、反相微乳法、化学气相沉积法、双层包覆法和改性树脂包覆法在铁基软磁复合材料的SiO_(2)绝缘包覆上的应用,归纳了上述各绝缘包覆方法的特点,并按其特点进行了分类,指出了当前SiO_(2)绝缘包覆面临的一些问题,并对未来绝缘包覆方法的发展进行了展望。

Electromagnetic Characteristics and Corrosion Resistance of New Magnetosoft Materials Based on Capsulated Iron Powders

A new method of depositing an insulating multifunctional oxide coating on metal particles was developed.Such coatings increase corrosion resistance and insulate metal particles from each other.On base of capsulated by oxide coating water-atomized iron powder ASC100.29,new composite soft magnetic materials were synthesized,which are able of replacing electrical steel in devices.Structural,electromagnetic properties and corrosion characte-ristics of the obtained composites were studied.It was found that the synthesized composite materials have low elec-tromagnetic losses,high values of magnetic induction(up to 2.1 T)and good corrosion resistance.The results demon-strate that the use of such materials in power supplies,c hokes,transformers,stators and rotors of electric machines and other products ensures their stable operation under various conditions.