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<p>Organic weak acid passivation methods have gained attention in the preparation of soft magnetic powder cores due to their environmental friendliness and in-situ oxidation ability. However, the formation mechanism of the insulation coating layer and the impact of processing parameters on magnetic properties have not been thoroughly investigated. This study examines the effect of acetic acid concentration on the formation of the Al<sub>2</sub>O<sub>3</sub> coating layer on the surface of FeSiAl powder and its influence on the performance of soft magnetic powder cores. By varying the acetic acid solution concentration (0.05–0.25&#xa0;mol/L), the thickness and uniformity of the coating layer were successfully controlled, significantly optimizing the electromagnetic properties of the FeSiAl powder. The results show that when the acetic acid concentration is 0.20&#xa0;mol/L, the FeSiAl@Al<sub>2</sub>O<sub>3</sub> soft magnetic powder core exhibits exceptional electromagnetic response characteristics in high-frequency applications, combining high permeability (35.3) and low power loss (109.6&#xa0;kW/m<sup>3</sup>), a typically mutually exclusive performance combination. Microscopic structural analysis reveals that the appropriate Al<sub>2</sub>O<sub>3</sub> coating effectively reduces eddy current loss while maintaining high permeability and excellent frequency stability. Further first-principles calculations and surface analysis demonstrate that the strong bonding between the FeSiAl matrix and the Al<sub>2</sub>O<sub>3</sub> coating imparts superior electrical insulation properties and low-loss characteristics to the material. This study provides a theoretical foundation and technical support for the sustainable design of high-frequency, high-power magnetic components, while also offering a novel approach for optimizing the soft magnetic powder core preparation process.</p>

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In-situ coating of FeSiAl soft magnetic powder core via acetic acid passivation and the high-frequency performance optimization

  • 期刊论文

  • 发表日期：

    2025年10月6日

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  • Rongjian Cui,
  • Xianbao Zhang,
  • Jun Wang,
  • Kaixuan Li,
  • Zhifang Gao,
  • Zhaoyang Wu

摘要

Organic weak acid passivation methods have gained attention in the preparation of soft magnetic powder cores due to their environmental friendliness and in-situ oxidation ability. However, the formation mechanism of the insulation coating layer and the impact of processing parameters on magnetic properties have not been thoroughly investigated. This study examines the effect of acetic acid concentration on the formation of the Al2O3 coating layer on the surface of FeSiAl powder and its influence on the performance of soft magnetic powder cores. By varying the acetic acid solution concentration (0.05–0.25 mol/L), the thickness and uniformity of the coating layer were successfully controlled, significantly optimizing the electromagnetic properties of the FeSiAl powder. The results show that when the acetic acid concentration is 0.20 mol/L, the FeSiAl@Al2O3 soft magnetic powder core exhibits exceptional electromagnetic response characteristics in high-frequency applications, combining high permeability (35.3) and low power loss (109.6 kW/m3), a typically mutually exclusive performance combination. Microscopic structural analysis reveals that the appropriate Al2O3 coating effectively reduces eddy current loss while maintaining high permeability and excellent frequency stability. Further first-principles calculations and surface analysis demonstrate that the strong bonding between the FeSiAl matrix and the Al2O3 coating imparts superior electrical insulation properties and low-loss characteristics to the material. This study provides a theoretical foundation and technical support for the sustainable design of high-frequency, high-power magnetic components, while also offering a novel approach for optimizing the soft magnetic powder core preparation process.