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Enhanced AC magnetic properties of Fe-based soft magnetic composites coated with an electrically insulated SiO2–ZrO2 layer

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Abstract

Insulating Fe@SiO2–ZrO2 (FSZ) composite powders were synthesized by a co-precipitation method and the corresponding soft magnetic composites (SMCs) were fabricated with the powder metallurgy technique. The FSZ powders fabricated with 80 mmol/L tetraethyl orthosilicate and 20–40 mmol/L ZrOCl2·8H2O exhibits a dense and uniform SiO2–ZrO2 insulating layer with high Si–O and Zr–O binding energies, high saturation magnetization (Ms > 200.4 emu/g), and low coercivity (Hci, < 45.9 Oe). Compared with Fe@SiO2 SMCs, Fe@SiO2–ZrO2 SMCs have a higher resistivity of 941.9–984.2 μΩ m, and most of the eddy current losses are suppressed, contributing to superior alternating current magnetic properties, including a flat frequency character up to 1 MHz, lower core loss (Ps) of 17.9–19.2 W/kg (20 mT/100 kHz) and high permeability (μm) of 64–73. Electron probe microanalysis measurements confirmed that Fe powders are fully separated by a thin insulating layer composed of a large amount of SiO2 and a small fraction of ZrO2, which displays outstanding pressure resistance and thermal stability characteristics and contributes to the fabrication of SMCs with high resistivity and low core loss.

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Acknowledgements

This project was supported by the National Natural Science Foundation of China (Grant No. 51574293).

Funding

This project was supported by the National Natural Science Foundation of China (Grant No. 51574293).

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Authors and Affiliations

  1. State Key Laboratory for Powder Metallurgy, Central South University, Changsha, 410083, China

    Zhi Gao, Liya Li, Yicheng Ge & Qiuli Chen

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  1. Zhi Gao
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  2. Liya Li
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  3. Yicheng Ge
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  4. Qiuli Chen
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Contributions

Conceptualization: [ZG], [LL]; Methodology: [ZG], [LL], [YG], [QC]; Formal analysis and investigation: [ZG]; Writing—original draft preparation: [ZG]; Writing—review and editing: [LL], [ZG]; Funding acquisition: [LL]; Resources: [YG]; Supervision: [YG].

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Correspondence to Liya Li or Yicheng Ge.

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Gao, Z., Li, L., Ge, Y. et al. Enhanced AC magnetic properties of Fe-based soft magnetic composites coated with an electrically insulated SiO2–ZrO2 layer. J Mater Sci: Mater Electron 32, 14944–14955 (2021). https://doi.org/10.1007/s10854-021-06046-7

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