Liu J, Dong Y, Zhu Z, Zhao H, Pang J, Wang P, Zhang J. Fe-Based Amorphous Magnetic Powder Cores with Low Core Loss Fabricated by Novel Gas-Water Combined Atomization Powders.
MATERIALS (BASEL, SWITZERLAND) 2022;
15:6296. [PMID:
36143607 PMCID:
PMC9503578 DOI:
10.3390/ma15186296]
[Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 07/30/2022] [Revised: 09/02/2022] [Accepted: 09/08/2022] [Indexed: 06/16/2023]
Abstract
FeSiBCCr amorphous powders were produced by a novel gas-water combined atomization process, and the corresponding MPCs (magnetic powder cores) were subsequently fabricated by phosphating treatment (0.4~1.6 wt.%), cold pressing (550~2350 MPa), and annealing (423~773 K), respectively. The results showed that the powders had high circularity, excellent thermal stability (ΔT = 59 K), and high saturation magnetization (0.83 T), which could provide raw powders for high-performance MPCs. With increasing phosphoric acid concentrations, despite the increase in DC-bias%, the uniformity of the insulation layers deteriorated, which led to a decrease in permeability and an increase in core loss. With increasing compaction pressures, the core loss increased continuously, and the permeability and DC-bias% first increased and then decreased. When annealing below the crystallization temperature, with increasing annealing temperatures, the permeability increased, and the core loss and DC-bias% decreased continuously. Under the optimized process of 0.4 wt.% phosphating concentration, 550 MPa pressure, and 773 K annealing temperature, the MPCs had a permeability of 21.54 ± 1.21, DC-bias% of 90.3 ± 0.2, and a core loss (Bm = 50 mT, f = 100 kHz) of 103.0 ± 26.3 mW cm-3. The MPCs had excellent high-frequency low-loss characteristics and showed great application potential under the development trends of high current, high power, and high frequency of electronic components.
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