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<p>With the increasing demand for high-performance soft magnetic composites (SMCs) in power electronics, scalable fabrication of SiO<sub>2</sub>-insulated FeNi SMCs remains a research hotspot while mature preparation technologies are still insufficient. This work systematically investigates the evolution of the coating process and microstructure during scale-up from 50 (gram level) to 1000&#xa0;g (kilogram level). Proportionally increasing tetraethyl orthosilicate (TEOS) dosage from 1 (T-1) to 20&#xa0;mL (T-20) fails to form a uniform, dense SiO<sub>2</sub> layer, which is attributed to reduced silanol concentration caused by pH variation. Adjusting the system pH with aqueous ammonia can boost SiO<sub>2</sub> content to a certain extent, yet the improvement remains constrained by silicon source concentration. By optimizing TEOS dosage to 40&#xa0;mL (T-40), a dense, smooth, and uniform SiO<sub>2</sub> coating is successfully obtained owing to enhanced reaction kinetics and increased silanol concentration. The T-40 powder has a silicon content of 1.7919%, close to that of T-1 (1.3716%). Correspondingly, T-40 SMCs exhibit higher core density, higher resistivity, and better anti-saturation performance, with comparable effective permeability and core loss to T-1 SMCs. Additionally, the optimized TEOS dosage endows the powder with good flowability, high thermal stability and high corrosion resistance relative to raw FeNi powder, facilitating industrial SMCs fabrication. This work provides a feasible route and novel reference for the scalable industrial production of high-performance SiO<sub>2</sub>-insulated FeNi powders.</p>

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Microstructure evolution and performance regulation of SiO2-insulated FeNi soft magnetic composites during scale-up fabrication

  • 期刊论文

  • 发表日期：

    2026年6月16日

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  • Yuting Liu,
  • Wei Liu,
  • Ziyi Huang,
  • Hong Yuan,
  • Xuebin Zhang,
  • Hailin Su

摘要

With the increasing demand for high-performance soft magnetic composites (SMCs) in power electronics, scalable fabrication of SiO2-insulated FeNi SMCs remains a research hotspot while mature preparation technologies are still insufficient. This work systematically investigates the evolution of the coating process and microstructure during scale-up from 50 (gram level) to 1000 g (kilogram level). Proportionally increasing tetraethyl orthosilicate (TEOS) dosage from 1 (T-1) to 20 mL (T-20) fails to form a uniform, dense SiO2 layer, which is attributed to reduced silanol concentration caused by pH variation. Adjusting the system pH with aqueous ammonia can boost SiO2 content to a certain extent, yet the improvement remains constrained by silicon source concentration. By optimizing TEOS dosage to 40 mL (T-40), a dense, smooth, and uniform SiO2 coating is successfully obtained owing to enhanced reaction kinetics and increased silanol concentration. The T-40 powder has a silicon content of 1.7919%, close to that of T-1 (1.3716%). Correspondingly, T-40 SMCs exhibit higher core density, higher resistivity, and better anti-saturation performance, with comparable effective permeability and core loss to T-1 SMCs. Additionally, the optimized TEOS dosage endows the powder with good flowability, high thermal stability and high corrosion resistance relative to raw FeNi powder, facilitating industrial SMCs fabrication. This work provides a feasible route and novel reference for the scalable industrial production of high-performance SiO2-insulated FeNi powders.