<p>Low core loss and high permeability Fe-5.5&#xa0;wt.% Si soft magnetic composites (SMCs) are fabricated based on particle grading. Spherical Fe-Si powder was divided into five particle size grades, and three particle size fractions were selected and mixed in an optimized ratio to improve the bulk density of the SMCs and reduce eddy currents between particles. The SMCs obtained from the experiment exhibited superior magnetic performance, with magnetic permeability reaching 108 and core loss as low as 1335 mW/cm<sup>3</sup> at 100&#xa0;kHz and 100 mT. Compared to the original and commercial powders, the optimized graded mixture demonstrates higher density, improved magnetic permeability, and significantly reduced core losses, thereby validating the effectiveness of particle size grading in enhancing the magnetic properties of SMCs for engineering applications.</p>

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Fabrication of Fe-5.5 wt.% Si Soft Magnetic Composites with Low Core Loss and High Permeability via Particle Size Grading

  • Chunsheng Ju,
  • Yong Zhu,
  • Siyu Deng,
  • Zhilong Shi,
  • Chenyang Han,
  • Kai Zhu,
  • Xucai Kan,
  • Shuangjiu Feng,
  • Wei Sun,
  • Xiansong Liu

摘要

Low core loss and high permeability Fe-5.5 wt.% Si soft magnetic composites (SMCs) are fabricated based on particle grading. Spherical Fe-Si powder was divided into five particle size grades, and three particle size fractions were selected and mixed in an optimized ratio to improve the bulk density of the SMCs and reduce eddy currents between particles. The SMCs obtained from the experiment exhibited superior magnetic performance, with magnetic permeability reaching 108 and core loss as low as 1335 mW/cm3 at 100 kHz and 100 mT. Compared to the original and commercial powders, the optimized graded mixture demonstrates higher density, improved magnetic permeability, and significantly reduced core losses, thereby validating the effectiveness of particle size grading in enhancing the magnetic properties of SMCs for engineering applications.