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<p>With the extensive application of third-generation semiconductor devices in the drive motors of new energy vehicles, soft magnetic composites (SMCs) have attracted much attention owing to their excellent direct current (DC) bias characteristics and high saturation magnetic induction intensity. However, SMCs still face the “permeability-loss” trade-off dilemma in high-frequency and high-power density applications. In this study, an environmentally friendly acetic acid passivation strategy was innovatively adopted to <i>in situ</i> generate a uniform and continuous Al<sub>2</sub>O<sub>3</sub> insulating layer on the surface of flaky FeSiAl powders. By systematically regulating the acetic acid passivation time (20–100&#xa0;min), FeSiAl–Al<sub>2</sub>O<sub>3</sub> SMCs with different Al<sub>2</sub>O<sub>3</sub> coating characteristics were prepared, and their magnetic properties were characterized in detail. The experimental results show that when the acetic acid passivation time is 60&#xa0;min, the FeSiAl–Al<sub>2</sub>O<sub>3</sub> SMCs achieve a synergistic breakthrough in ultra-high permeability (97.6 @2&#xa0;MHz), ultra-low power loss (93.6&#xa0;kW/m<sup>3</sup> @50 mT/100&#xa0;kHz), and strong DC bias stability (&gt;70%71.98 Oe) simultaneously, showing excellent comprehensive magnetic properties. This study provides new ideas and technical support for the development of high-performance and green-manufactured SMCs, and is expected to achieve more efficient electromagnetic energy conversion in high-frequency and high-power density application scenarios.</p>

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Nanoarchitectonics of Surface Insulation Layer of Lamellar FeSiAl Powder via Acetic Acid Passivation and Optimization of Magnetic Properties of Soft Magnetic Composites

  • 期刊论文

  • 发表日期：

    2025年10月22日

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  • Rongjian Cui,
  • Xianbao Zhang,
  • Jun Wang,
  • Li Liu,
  • Zhifang Gao,
  • Huaqin Huang

摘要

With the extensive application of third-generation semiconductor devices in the drive motors of new energy vehicles, soft magnetic composites (SMCs) have attracted much attention owing to their excellent direct current (DC) bias characteristics and high saturation magnetic induction intensity. However, SMCs still face the “permeability-loss” trade-off dilemma in high-frequency and high-power density applications. In this study, an environmentally friendly acetic acid passivation strategy was innovatively adopted to in situ generate a uniform and continuous Al2O3 insulating layer on the surface of flaky FeSiAl powders. By systematically regulating the acetic acid passivation time (20–100 min), FeSiAl–Al2O3 SMCs with different Al2O3 coating characteristics were prepared, and their magnetic properties were characterized in detail. The experimental results show that when the acetic acid passivation time is 60 min, the FeSiAl–Al2O3 SMCs achieve a synergistic breakthrough in ultra-high permeability (97.6 @2 MHz), ultra-low power loss (93.6 kW/m3 @50 mT/100 kHz), and strong DC bias stability (>70%71.98 Oe) simultaneously, showing excellent comprehensive magnetic properties. This study provides new ideas and technical support for the development of high-performance and green-manufactured SMCs, and is expected to achieve more efficient electromagnetic energy conversion in high-frequency and high-power density application scenarios.