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Soft magnetic properties, microstructure, and growth mechanism of FeSiAl soft magnetic powder cores fabricated via hexafluozirconic acid passivation

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Abstract

In order to develop FeSiAl soft magnetic powder cores (SMPCs) with excellent soft magnetic properties, FeSiAl powder passivated by hexafluorozirconic acid (H2ZrF6) was sucessfully prepared and the effect of different concentrations of H2ZrF6 on the effective permeability (μe) and core loss (Pcv) of FeSiAl SMPCs were systematically studied. H2ZrF6 (0.1 wt% of FeSiAl powder) passivation successfully optimized the soft magnetic properties, when the μe reached 94, the Pcv was only 180 mW/cm3 at 0.05 T and 100 kHz. SEM, XRD, FTIR, XPS, and TEM were used to investigate the microstructure and growth mechanism of the coating layer. The FeSiAl powder was passivated by H2ZrF6 to form a composite coating layer with dominating Fe2O3, Al2O3, SiO2, ZrF4 and a small amount of AlF3, ZrO2, while the AlF3 and ZrO2 content increased significantly after annealing. In addition, this study effectively improved the high frequency characteristics of FeSiAl SMPCs and analyzed the generation of coating layer, providing a feasible way for the insulation treatment of soft magnetic powder cores.

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Funding

This work was supported by Youth Innovation Promotion Association CAS (Grant No. 2021294), the S&T Innovation 2025 Major Special Program (Grant No. 2021Z038), K.C. Wong Magna Fund in Ningbo University, and the “Pioneer and Leading Goose” R&D Program of Zhejiang (Grant No. 2023C01138).

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  1. Faculty of Materials Science and Chemical Engineering, Ningbo University, Ningbo, 315211, China

    Junyao Zhang & ** Yang, Aina He & Jiawei Li

  2. University of Chinese Academy of Sciences, Bei**g, 100049, China

    Yaqiang Dong, Aina He & Jiawei Li

  3. Hengdian Group DMEGC Magnetics Co., Ltd., Hengdian Industrial Area, Dongyang, 322118, China

    Lingwen Cai & Lidong Liu

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  1. Junyao Zhang
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Zhang, J., Lu, H., Dong, Y. et al. Soft magnetic properties, microstructure, and growth mechanism of FeSiAl soft magnetic powder cores fabricated via hexafluozirconic acid passivation. J Mater Sci: Mater Electron 35, 747 (2024). https://doi.org/10.1007/s10854-024-12481-z

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