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Improved magnetic properties of iron-based soft magnetic composites with a double phosphate-SiO2 shells structure

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Abstract

Herein a double shells structure was proposed to overcome the drawbacks such as poor heat resistance, incomplete insulation and high core loss coating of iron-based soft magnetic composites (SMCs) with single shell structure. The surface of the iron powder was coated with a double shells structure composed of an inner phosphate coating and an outer SiO2 coating through phosphating and hydrolysis successively. Subsequently, the effects of different SiO2 addition amount on the microstructure of iron powder and magnetic properties of SMCs were studied. The introduction of SiO2 in the double shells structure inhibited the decomposition and failure of phosphating layer after being annealed at a high temperature. The iron powder coated with the phosphate-SiO2 insulating layer was still effective after annealing in a N2 atmosphere at 570 °C, achieving the purpose of eliminating residual stress and improving magnetic properties. The optimal process parameters were set at 0.2 wt% phosphoric acid and 0.5 wt% tetraethyl orthosilicate to fabricate the phosphate-SiO2 double shells. The iron-based SMCs presented excellent magnetic properties with Bs of 1.29 T and Ps of 169.2 W/kg (measured at 1 T and 1 kHz). In addition, the core loss of SMCs introduced with SiO2 is 83% lower than that of SMCs produced by the phosphating process. This paper provides a feasible method for improving the magnetic properties of SMCs.

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Acknowledgements

The authors gratefully acknowledge the financial supports by the Science and Technology Commission of Shanghai Municipality (18040501500), the Innovation Program of Shanghai Municipal Education Commission (Grant No. 2019-01-07-00-10-E00053), the National Natural Science Foundation of China (Grant No. 51803119, 51871146 and 51771108), Chenguang Program supported by Shanghai Education Development Foundation and Shanghai Municipal Education Commission (Grant No. 18CG56), the Natural Science Foundation of Shanghai (18ZR1417000) and Shanghai Engineering Technology Research Centre of Deep Offshore Material (19DZ2253100).

Funding

The authors gratefully acknowledge the financial supports by the Science and Technology Commission of Shanghai Municipality (18040501500), the Innovation Program of Shanghai Municipal Education Commission (Grant No. 2019-01-07-00-10-E00053), the National Natural Science Foundation of China (Grant No. 51803119, 51871146 and 51771108), Chenguang Program supported by Shanghai Education Development Foundation and Shanghai Municipal Education Commission (Grant No. 18CG56), the Natural Science Foundation of Shanghai (18ZR1417000) and Shanghai Engineering Technology Research Centre of Deep Offshore Material (19DZ2253100).

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Authors and Affiliations

  1. College of Ocean Science and Engineering, Shanghai Maritime University, Shanghai, 201306, People’s Republic of China

    Wanli Yuan, Kai Sun, Jiahong Tian, Yaping Li, Zongxiang Wang, Boyang Liu & Runhua Fan

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  1. Wanli Yuan
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  2. Kai Sun
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  3. Jiahong Tian
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  4. Yaping Li
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  5. Zongxiang Wang
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  6. Boyang Liu
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  7. Runhua Fan
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Contributions

WY: methodology, data curation, validation, writing-original draft. KS: writing-review and editing, project administration, supervision. JT: formal analysis, software, supervision. YL: formal analysis, resources. ZW: resources, software. BL: supervision, validation. RF: supervision, funding acquisition, investigation.

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Correspondence to Kai Sun or Runhua Fan.

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I would like to declare on behalf of my co-authors that the work described is original research that has not been published previously, and not under consideration for publication elsewhere.

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Yuan, W., Sun, K., Tian, J. et al. Improved magnetic properties of iron-based soft magnetic composites with a double phosphate-SiO2 shells structure. J Mater Sci: Mater Electron 32, 21472–21482 (2021). https://doi.org/10.1007/s10854-021-06656-1

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