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Fe-Si-Al Soft Magnetic Composites with Significantly Reduced Core Loss via Constructing Uniform TiO2 Insulation Layer

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Abstract

Core–shell structured Fe-Si-Al@TiO2 with uniform coating layers have been used for preparing soft magnetic composites (SMCs) with good magnetic properties. The quality of the TiO2 insulation layer has been optimized by tuning the content of tetrabutyl titanate (TBOT), the reaction time, and the volume of acetic acid. It is proved that the conditions of 5 ml TBOT, 1-h reaction time, and 100 µl acetic acid would lead to uniform and dense TiO2 layer. As a result, the high-frequency eddy-current loss can be effectively decreased, which is related with increased resistivity. Moreover, optimal Fe-Si-Al@TiO2 powders would ensure high density of SMCs, resulting in high effective permeability and low hysteresis loss. When the effective permeability of optimal SMCs reaches 85 (measured at 100 kHz/1 V), the core loss is only 691.33 mW/cm3 (measured at 500 kHz/50 mT), which is much lower than those of Fe-Si-Al SMCs insulated with Al2O3 and phosphate. Owing to high-quality TiO2 insulating layer, as-prepared SMCs show unique superiority in achieving high effective permeability and low core loss simultaneously, in contrast with other reported SMCs. This work may provide novel insights into the synthesis of SMCs with excellent magnetic properties via building uniform oxide coating layer.

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Funding

This work was supported by the Major Project of Science and Technology Innovation 2025 in Ningbo City, China (No. 2020Z062), the Science and Technology Project of State Grid Corporation of China (No. 5500-202118252A-0–0-00), the Huaian Transformation Project of Sci-tech Achievement (No. HA201907), the Fundamental Research Funds for the Central Universities (No. JZ2021HGTA0174), and the Grant Project of Shenzhen Microgate Technology Co. Ltd (2021–2024).

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Authors and Affiliations

  1. Engineering Research Center of High Performance Copper Alloy Materials and Processing, Ministry of Education, Hefei University of Technology, Hefei, 230009, People’s Republic of China

    Xuyong Chen, Zhi Cao, Xudong Zeng, Kun Wan, Wei Liu & Hailin Su

  2. School of Materials Science and Engineering and Anhui Provincial Key Laboratory of Advanced Functional Materials and Devices, Hefei University of Technology, Hefei, 230009, People’s Republic of China

    Xuyong Chen, Zhi Cao, Xudong Zeng, Kun Wan, Wei Liu & Hailin Su

  3. Huaian Engineering Research Center of Soft Magnetic Powder Cores and Devices, Jiangsu Red Magnetic Materials Incorporation, Xuyi, 211700, People’s Republic of China

    Wei Liu, Hailin Su & Zhongqiu Zou

  4. Anhui Red Magneto-Electric Technology Co., Ltd, Wuhu, 241002, People’s Republic of China

    Wei Liu, Hailin Su & Zhongqiu Zou

  5. Robotics Institute, Ningbo University of Technology, Ningbo, 315211, People’s Republic of China

    Jinzhi Wang

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  1. Xuyong Chen
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Correspondence to Wei Liu, Hailin Su or Jinzhi Wang.

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Chen, X., Cao, Z., Zeng, X. et al. Fe-Si-Al Soft Magnetic Composites with Significantly Reduced Core Loss via Constructing Uniform TiO2 Insulation Layer. J Supercond Nov Magn 35, 1975–1985 (2022). https://doi.org/10.1007/s10948-022-06289-3

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