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<p>Soft magnetic composites (SMCs) are crucial for high-frequency power applications. FeSiAl alloys offer high saturation flux density but suffer from high losses. This study investigates the enhancement of high-frequency electromagnetic properties of injection-molded FeSiAl SMCs through powder annealing. Spherical FeSiAl powder was annealed at temperatures ranging from 600 to 900&#xa0;°C and then compounded with epoxy resin to fabricate toroidal cores via a low-pressure injection molding process. The effects of annealing on microstructure, complex permeability, and core loss were systematically characterized. XRD analysis indicated that annealing promoted a structural transition from a disordered face-centered cubic (fcc) solid solution to an ordered superlattice. Optimal annealing at 850&#xa0;°C significantly increased the permeability by 21.1% (to 18.3 @ 1&#xa0;MHz, 20 mT), while annealing at 800&#xa0;°C minimized the core loss by 55.3% (to 352.7 mW/cm<sup>3</sup> @ 1&#xa0;MHz, 20 mT). The improvement is attributed to the effective relief of internal stress and enhanced domain wall mobility, though competing mechanisms lead to slightly different optimal temperatures for permeability and loss. The injection molding process avoids insulation layer damage associated with high-pressure compaction, making these FeSiAl SMCs promising for high-frequency applications like 5G and advanced power electronics.</p>

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Improving the Electromagnetic Properties of FeSiAl Soft Magnetic Composites Fabricated by Injection Molding

  • 期刊论文

  • 发表日期：

    2026年1月27日

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  • Huamin Gao,
  • Cong Zhang,
  • Shuangjiu Feng,
  • Xucai Kan,
  • Xiansong Liu,
  • Mingling Li

摘要

Soft magnetic composites (SMCs) are crucial for high-frequency power applications. FeSiAl alloys offer high saturation flux density but suffer from high losses. This study investigates the enhancement of high-frequency electromagnetic properties of injection-molded FeSiAl SMCs through powder annealing. Spherical FeSiAl powder was annealed at temperatures ranging from 600 to 900 °C and then compounded with epoxy resin to fabricate toroidal cores via a low-pressure injection molding process. The effects of annealing on microstructure, complex permeability, and core loss were systematically characterized. XRD analysis indicated that annealing promoted a structural transition from a disordered face-centered cubic (fcc) solid solution to an ordered superlattice. Optimal annealing at 850 °C significantly increased the permeability by 21.1% (to 18.3 @ 1 MHz, 20 mT), while annealing at 800 °C minimized the core loss by 55.3% (to 352.7 mW/cm3 @ 1 MHz, 20 mT). The improvement is attributed to the effective relief of internal stress and enhanced domain wall mobility, though competing mechanisms lead to slightly different optimal temperatures for permeability and loss. The injection molding process avoids insulation layer damage associated with high-pressure compaction, making these FeSiAl SMCs promising for high-frequency applications like 5G and advanced power electronics.