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<p>FeSi magnetic powder cores suffer from high eddy current losses at high frequencies due to insufficient electrical insulation between particles. To mitigate this shortcoming, we developed a nano-Al<sub>2</sub>O<sub>3</sub> coating using a physical mixing method and an aqueous sodium silicate as the binder. Magnetic cores were fabricated by pressing the FeSi powder particles coated by nano-Al<sub>2</sub>O<sub>3</sub> with different additions at 1800&#xa0;MPa, and annealing at 710&#xa0;°C. The results indicate that a uniform and continuous coating is obtained at optimal addition of 3 wt % Al<sub>2</sub>O<sub>3</sub>, .at which core loss reaches a minimum of 246.68 mW/cm<sup>3</sup> (100&#xa0;kHz/50 mT) due to eddy current loss is effectively suppressed, and the <i>DC</i>-bias performance reaches 68.3% while maintaining high saturated magnetization due to minimal magnetic dilution. Those magnetic properties are superior to most of magnetic composite materials. The FeSi cores with optimal Al<sub>2</sub>O<sub>3</sub> coating exhibit competitive soft magnetic properties, and low cost suitable for industrial production.</p>

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The excellent soft magnetic properties of FeSi magnetic powder cores coated with nano-Al2O3 granules

  • 期刊论文

  • 发表日期：

    2026年5月22日

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  • Yangshuwen Sun,
  • Xin Yu,
  • Xue Yang,
  • Wei Zhang,
  • Ming Zhang,
  • Dong Yang,
  • Jing Pang,
  • Keqiang Qiu

摘要

FeSi magnetic powder cores suffer from high eddy current losses at high frequencies due to insufficient electrical insulation between particles. To mitigate this shortcoming, we developed a nano-Al2O3 coating using a physical mixing method and an aqueous sodium silicate as the binder. Magnetic cores were fabricated by pressing the FeSi powder particles coated by nano-Al2O3 with different additions at 1800 MPa, and annealing at 710 °C. The results indicate that a uniform and continuous coating is obtained at optimal addition of 3 wt % Al2O3, .at which core loss reaches a minimum of 246.68 mW/cm3 (100 kHz/50 mT) due to eddy current loss is effectively suppressed, and the DC-bias performance reaches 68.3% while maintaining high saturated magnetization due to minimal magnetic dilution. Those magnetic properties are superior to most of magnetic composite materials. The FeSi cores with optimal Al2O3 coating exhibit competitive soft magnetic properties, and low cost suitable for industrial production.