1. Novel Fabrication Method for a High-Performance Soft-Magnetic Composite Composed of Alumina-Coated Fe-Based Metal Powder
- Author
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Sunwoo Lee, Seong Jin Choi, Sang-Im Yoo, Chris Yeajoon Bon, Kang-Hyuk Lee, and Sungjoon Choi
- Subjects
010302 applied physics ,Materials science ,Alloy ,Composite number ,02 engineering and technology ,Molding (process) ,engineering.material ,021001 nanoscience & nanotechnology ,Condensed Matter Physics ,01 natural sciences ,Electronic, Optical and Magnetic Materials ,Surface coating ,Carbonyl iron ,Coating ,0103 physical sciences ,Materials Chemistry ,engineering ,Metal powder ,Electrical and Electronic Engineering ,Composite material ,0210 nano-technology ,Sendust - Abstract
A high-performance soft-magnetic composite (SMC) has been successfully fabricated in a toroidal mold without the application of compaction pressure by mixing three different alumina-coated Fe-based metal powders, namely carbonyl iron (FM), Fe-Si-Cr alloy (FSC), and Fe-Si-Al alloy (sendust), with epoxy resin in a centrifugal paste mixer. Surface coating with an alumina layer was performed via a sol–gel process, and its thickness was controlled by varying the coating time. Without the alumina coating, the SMC toroidal core with a FM:FSC:sendust mixing ratio of 8:22:70 by mass exhibited optimal magnetic properties including an effective permeability (μeff) of 33.9 and total core loss (Pt) of 252 mW/cm3 at 100 kHz with an amplitude (B) of 50 mT. With the alumina coating, however, the SMC toroidal core with the same mixing ratio exhibited a significantly reduced Pt value of 213 mW/cm3 while its μeff value was slightly decreased to 32.4, primarily due to the suppression of the macroscopic eddy-current loss from 115 mW/cm3 to 85 mW/cm3. These results indicate that an optimal mixture of the three different alumina-coated Fe-based metal powders is very effective for fabricating high-performance SMC cores without external pressure for molding, being applicable for miniature electronic components.
- Published
- 2020
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