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<p>This study systematically investigated the effects of pre-annealing, particle-size regulation, and phosphoric acid passivation on the microstructure and magnetic properties of FeSiAl soft magnetic composites. Pre-annealing at 750&#xa0;°C for 1&#xa0;h retained the spherical morphology of FeSiAl powders while inducing the formation of an Al-rich oxide layer on the particle surfaces. This surface oxide layer modified the interfacial state of the powders and contributed to loss suppression, although the effective permeability decreased from 78.33 to 69.53. Particle-size regulation showed that the 400-mesh powder achieved the best balance between permeability retention and core-loss reduction, with a core loss of 11.64 mW/cm<sup>3</sup> under 100&#xa0;Hz/50 mT. After phosphoric acid passivation, a P- and O-containing phosphate insulating layer was formed on the powder surfaces. Increasing the phosphoric acid content enhanced interparticle insulation but also reduced permeability because of the increased nonmagnetic phase fraction. The optimized composite was obtained using 400-mesh FeSiAl powders pre-annealed at 750&#xa0;°C for 1&#xa0;h and passivated with 0.2 wt.% phosphoric acid, exhibiting a low core loss of 11.64 mW/cm<sup>3</sup> under 100&#xa0;Hz/50 mT, an effective permeability of 69.53, and a permeability retention of 44.24% under a DC-bias field of 100 Oe. These results demonstrate that the synergistic regulation of surface oxidation, particle size, and phosphate passivation is an effective strategy for developing low-loss FeSiAl soft magnetic composites.</p>

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Magnetic performance optimization of FeSiAl soft magnetic composites with low core loss and stable direct-current bias response

  • 期刊论文

  • 发表日期：

    2026年7月5日

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  • Yifan Li,
  • Zhengqu Zhu,
  • Pu Wang,
  • Jiaquan Zhang

摘要

This study systematically investigated the effects of pre-annealing, particle-size regulation, and phosphoric acid passivation on the microstructure and magnetic properties of FeSiAl soft magnetic composites. Pre-annealing at 750 °C for 1 h retained the spherical morphology of FeSiAl powders while inducing the formation of an Al-rich oxide layer on the particle surfaces. This surface oxide layer modified the interfacial state of the powders and contributed to loss suppression, although the effective permeability decreased from 78.33 to 69.53. Particle-size regulation showed that the 400-mesh powder achieved the best balance between permeability retention and core-loss reduction, with a core loss of 11.64 mW/cm3 under 100 Hz/50 mT. After phosphoric acid passivation, a P- and O-containing phosphate insulating layer was formed on the powder surfaces. Increasing the phosphoric acid content enhanced interparticle insulation but also reduced permeability because of the increased nonmagnetic phase fraction. The optimized composite was obtained using 400-mesh FeSiAl powders pre-annealed at 750 °C for 1 h and passivated with 0.2 wt.% phosphoric acid, exhibiting a low core loss of 11.64 mW/cm3 under 100 Hz/50 mT, an effective permeability of 69.53, and a permeability retention of 44.24% under a DC-bias field of 100 Oe. These results demonstrate that the synergistic regulation of surface oxidation, particle size, and phosphate passivation is an effective strategy for developing low-loss FeSiAl soft magnetic composites.