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<p>Insulation coating is crucial for soft magnetic composites (SMCs) to reduce eddy current loss. In this work, the oxides/SiO<sub>2</sub> double-layer coating, prepared via in situ oxidation followed by modified sol–gel process, was proposed as the insulation coating on FeSiAl powder to prepare FeSiAl/oxides/SiO<sub>2</sub> SMC. The microstructure of double-layer powder coating was compared with the single-layer powder coating and SiO<sub>2</sub>-coated phosphate powders. The properties of FeSiAl/oxides/SiO<sub>2</sub> SMC were also compared with the SMCs prepared from other powders. It is found that during the in situ oxidation with KMnO<sub>4</sub>, a composite oxide layer mainly consisting of Fe<sub>3</sub>O<sub>4</sub>, Fe<sub>2</sub>O<sub>3</sub>, Al<sub>2</sub>O<sub>3</sub>, MnO, and MnO<sub>2</sub> formed on the surface of FeSiAl powder. This oxide layer not only facilitated the adhesion of SiO<sub>2</sub> but also enhanced insulation performance. The modified sol–gel process improves the density and adhesion of the SiO<sub>2</sub> layer. As a result, the FeSiAl/oxides/SiO<sub>2</sub> SMC exhibits a relatively high effective permeability of 39 and low core loss of 86.6&#xa0;mW/cm<sup>3</sup> at 100&#xa0;kHz/50&#xa0;mT, surpassing the performance of many previously reported FeSiAl-based SMCs containing SiO<sub>2</sub> layer. The ultra-low core loss results from the double-layer insulation structure, which minimizes the hysteresis loss through uniform magnetization, reduces the eddy current loss owing to its superior insulation performance, and decreases the residual loss by enhanced uniformity of coating. In addition, the FeSiAl/oxides/SiO<sub>2</sub> SMC also demonstrated excellent DC bias performance with a permeability retention rate of 71.5% at 100&#xa0;Oe. Hence, this work provides a novel approach for enhancing the high-frequency performance of FeSiAl based&#xa0;SMCs.</p>

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Low magnetic loss of FeSiAl/oxides/SiO2 soft magnetic composites achieved by in situ oxidation and modified sol–gel coating

  • 期刊论文

  • 发表日期：

    2026年8月3日

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  • Ximeng Huang,
  • Tongxin Yuan,
  • Yang Zhou,
  • Hongya Yu,
  • Shuainan Xu,
  • Zhongwu Liu

摘要

Insulation coating is crucial for soft magnetic composites (SMCs) to reduce eddy current loss. In this work, the oxides/SiO2 double-layer coating, prepared via in situ oxidation followed by modified sol–gel process, was proposed as the insulation coating on FeSiAl powder to prepare FeSiAl/oxides/SiO2 SMC. The microstructure of double-layer powder coating was compared with the single-layer powder coating and SiO2-coated phosphate powders. The properties of FeSiAl/oxides/SiO2 SMC were also compared with the SMCs prepared from other powders. It is found that during the in situ oxidation with KMnO4, a composite oxide layer mainly consisting of Fe3O4, Fe2O3, Al2O3, MnO, and MnO2 formed on the surface of FeSiAl powder. This oxide layer not only facilitated the adhesion of SiO2 but also enhanced insulation performance. The modified sol–gel process improves the density and adhesion of the SiO2 layer. As a result, the FeSiAl/oxides/SiO2 SMC exhibits a relatively high effective permeability of 39 and low core loss of 86.6 mW/cm3 at 100 kHz/50 mT, surpassing the performance of many previously reported FeSiAl-based SMCs containing SiO2 layer. The ultra-low core loss results from the double-layer insulation structure, which minimizes the hysteresis loss through uniform magnetization, reduces the eddy current loss owing to its superior insulation performance, and decreases the residual loss by enhanced uniformity of coating. In addition, the FeSiAl/oxides/SiO2 SMC also demonstrated excellent DC bias performance with a permeability retention rate of 71.5% at 100 Oe. Hence, this work provides a novel approach for enhancing the high-frequency performance of FeSiAl based SMCs.