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This study used a traditional solid-state reaction method to prepare a series of composite ceramics in the 0.7Mg4Nb2O9-(0.3-x)ZnAl2O4-xTiO2 ternary system. Crystalline phases and microstructure of Mg4Nb2O9-ZnAl2O4-TiO2 dielectric ceramic composites were investigated and correlated with the relevant dielectric properties. It was observed that the addition of Ti4+ substituted Nb5+ in the Mg4Nb2O9 structure, which promoted the decomposition of Mg4Nb2O9 to form the second phase, Mg5Nb4O15, during sintering. The synergistic effect of ZnAl2O4-TiO2 co-doping promoted the Mg4Nb2O9 ceramic densification. The sample (0.7Mg4Nb2O9-(0.3-x)ZnAl2O4-xTiO2) with x = 0.15−0.2 exhibited dielectric constants of 13–14, larger than those of ZnAl2O4, Mg4Nb2O9 and Mg5Nb4O15, due to the NbO6 octahedra distortion resulting from the substitution of Al3+/Ti4+ for Nb5+ in Mg4Nb2O9 and Mg5Nb4O15. The long-range order of the NbO6 octahedra was enhanced by co-doping ZnAl2O4 and TiO2, thereby enhancing the Qxf value. A dielectric constant of 13.1, Qxf value of 366,000 GHz and a τf of −60.8 ppm/°C were obtained from 1300 °C sintered 0.7Mg4Nb2O9-0.15ZnAl2O4-0.15TiO2. These results show that 0.7Mg4Nb2O9-0.15 ZnAl2O4-0.15TiO2 ceramic is a good candidate for microwave electronic device applications.

⍺-alumina powder with an average particle size of 180 nm was dispersed into a photosensitive resin to prepare slurry with a solid content of 40 vol% in this study. The main defects in fabricating high-performance alumina ceramics using digital light processing (DLP) 3D printing are crossing cracks resulting from the tensile stress induced by constrained shrinkage during polymerization and delamination arising from insufficient adhesion between the printed layers. The different photocurable resin systems and different amounts of plasticizer, PEG400, effects on the defect formation, sintered density, and mechanical strength were investigated. It was observed that the optimal resin composition was made up of monomer (1,6-hexanediol diacrylate) and oligomer (Bisphenol A epoxy acrylate) at the ratio of 4:1. For the slurry with binder/plasticizer of 8:2, the sintered body defects can be completely eliminated and the sintered density and average flexural strength can reach 94% and 340 MPa, respectively.

This study investigated the effects of silver powder modification on intermetallic compound (IMC) formation and silver leaching during soldering at high temperatures. Silica nanoparticles (NPs) were deposited onto a silver powder surface to inhibit silver leaching, which can lead to soldering joint failure during high-temperature soldering. The NPs were deposited through hydrolysis and a condensation reaction of tetraethyl orthosilicate (TEOS) based on the Stöber method. Fourier transform infrared spectroscopy and scanning electron microscopy were used to observe the microstructures of silver powders after the deposition of silica NPs with various TEOS concentrations and various deposition times. As the deposition time increased, the amount of silica NPs on the surface of the silver powder increased. The transmission electron microscopy results show that silica NPs were located at the IMC grain boundaries, which can hinder the dissolution of IMCs by lead-free solder melt along grain boundaries during soldering, retarding silver leaching. The growth kinetics and mechanism of IMCs during soldering were investigated. The results show that the growth of IMCs is mainly dominated by bulk diffusion. The activation energy for IMC growth increased and the growth rate decreased with increasing silica NP addition and deposition time.

The effects of Na+ ions addition on the crystalline phases, microstructures, and varistor characteristics of ZnO–Co3O4–Pr6O11 ceramics were investigated using an X-ray diffractometer (XRD), scanning electron microscopy (SEM), and the electron probe microanalysis method (EPMA). The results indicate that the oxygen vacancies existing in Pr6O11 due to the substitution of Na+ for Pr ion could enhance the phase stability of Pr6O11, decrease the evaporation of Pr and promote the oxygen migration along the grain boundaries and oxygen ions chemisorbed at the grain boundaries. Therefore, the addition of sodium ions can effectively enhance the varistor properties of ZnO–Co3O4–Pr6O11 ceramics.

NiCo2S4 is one of the most promising bimetallic sulfides for use in energy-storage systems, but more studies are needed to endow NiCo2S4 with a high electrochemical reaction capability and reversibility. In this work, we present rationally materials design of an optimal NiCo2S4 nanoparticle in a reduced graphene oxide (RGO) matrix as a NiCo2S4/RGO nanocomposite. Furthermore, we report the improvements in the materials technology, demonstrating the NiCo2S4/RGO nanocomposite electrode with an excellent specific capacitance of 963–700 F g−1 at 1–15 A g−1, high capacitance retention of 70%, and long cycle life of 3000 cycles. The practical application is showcased in an asymmetric supercapacitor with a high active-material loading. The NiCo2S4/RGO nanocomposite shows a high energy density of 31 Wh kg−1 at a power density of 987 W kg−1 and maintains an excellent density of 23 Wh kg−1 at a high power density of 7418 W kg−1. The outstanding electrochemical utilization and stability of the NiCo2S4/RGO nanocomposite confirm that our systematic optimization in the materials science and technology in terms of the active-material synthesis, the electrode development, and the device design/fabrication would benefit the future development of high-performance supercapacitors.

The addition of glycerin reduced the dielectric constant of the aqueous alumina suspension, increased the zeta potential of the alumina powder, thickened the electric double layer, and improved the dispersibility of an alumina suspension for aqueous gel-casting. The glycerin-added suspension can effectively avoid the agglomeration, so that the green body had a more uniform microstructure and a higher relative density. The simultaneous addition of magnesium nitrate, EDTA and glycerol in aqueous-based alumina slurry can effectively promote the homogeneity of green microstructure and hence obtaining the sintered sample with relative sintered density of 99.7% and the mean grain size and distribution of 1.20 ± 0.44 μm. The (pressure-less sintered) sample Mg + EDTA + Gly exhibited superior Vickers hardness comparable to the samples prepared using HP, HIP, and SPS due to the small grain size (1.2 μm) and high sintered density (99.7%).

A molding coil is molded directly onto enameled wire using soft magnetic materials. When the molding coil size becomes smaller and thinner, the granules consisting of magnetic powder and organic binder cannot evenly fill the coil center column during molding, thereby causing cracks or deterioration in the products. In this study, FeSiCr alloy powder coils were prepared using gel casting. The structures and magnetic properties of coils prepared by dry pressing and gel casting were compared. The experimental results showed that the low-viscosity slurry used in the gel casting process can significantly improve the powder filling uniformity in the coil center. Gel casting protects the enameled wire from being damaged and short-circuited. FeSiCr alloy powder coils prepared using the gel casting process have higher inductance and better DC-bias superposition characteristics than those prepared using dry pressing. However, if the slurry viscosity for gel casting is too high, the powder packing in the coil center column becomes worse, which leads to a lower inductance value. The binder content in gel casting is also lower than that in dry pressing, resulting in a higher initial permeability with the same or higher mechanical strength as that prepared by dry pressing due to the more homogeneous binder distribution. For small-sized and high-inductance FeSiCr alloy powder coils, the problems of uneven packing and cracks in the coil center column can be effectively solved using the gel casting process.

Y2O3 transparent ceramics were fabricated by using vacuum sintering followed by hot isostatic pressing (HIPing). After HIP, large pores were eliminated, but a certain amount of nano-sized pores survived. Air annealing is required to bleach the as-HIPed ceramics. However, the annealing temperatures affected the transparency by affecting the evolution of the residual nano-pores. A high annealing temperature of ≥1600 °C resulted in obvious pore growth and loss of transparency of the samples. Pressure-less thermal expansion and shrinkage behaviors of the as-HIPed Y2O3 ceramics were studied in detail. The high annealing temperature (1600 °C) could lead to obvious swelling of both the pore sizes and the dimensions of the samples. It implies that the swelling of pores is not only from the diffusion and aggregation of the existing smaller pores, but may also from the thermal expansion of the high-pressure precipitated insoluble gas.

A molding coil is prepared by filling and dry pressing granulated alloy magnetic powders directly onto enameled wire. As the molding coil is developed toward miniaturization, the granules consisting of magnetic powder and organic binder cannot uniformly fill the small space in the coil center column during molding. This leads to a porous microstructure or cracks. The uneven packing problem in the coil center column was effectively solved in this study by applying a screen printing process using high-solid-content magnetic pastes. Bisphenol A epoxy resin has the benefits of excellent mechanical, bonding, electrical, corrosion resistance, low shrinkage and low cost properties. However, the viscosity is too high for use as a binder for high-solid-content magnetic paste. The magnetic paste viscosity can be reduced by substituting some low viscosity reactive diluent (butyl glycidyl ether) for Bisphenol A epoxy resin. It was observed that the relative density and magnetic properties (such as initial permeability, saturation magnetization, and core loss) can be effectively improved by increasing the monomer addition because the monomer acts as a lubricant that helps the magnetic particles rearrange during compaction. However, as monomer addition becomes greater than half the epoxy resin weight percent, the sample bending strength decreases.

A molded-type coil is prepared by filling and dry pressing granulated alloy magnetic powders directly onto enameled wire. As the molded-type coil is developed toward miniaturization, the granules consisting of magnetic powder and organic binder cannot uniformly fill the small space in the coil center column during molding. This leads to a porous microstructure or cracks. In this study, magnetic alloy powder coils were prepared using a screen-printing process using high-solid-content magnetic pastes. The magnetic powder was surface-modified with titanate coupling agent to improve the magnetic powder and epoxy resin compatibility, thereby improving magnetic powder mixing with epoxy resin and reducing the high solid content magnetic paste viscosity. The experimental results showed that the relative density and magnetic properties (such initial permeability, core loss, and coercivity) can be significantly enhanced using titanate coupling agent surface modification.

Passive components have continuously improved in recent years in miniaturization, multi-functionality, performance, and energy efficiency. The requirements of portable devices, home appliances, automobiles, industrial equipment, and other products demand these improvements. The passive components used in these products have had to continuously become smaller and thinner to meet ever-higher performance requirements. During the last several years, the demand for power inductors with high-rated current has increased rapidly due to the diversification and reduction in operating voltage in portable electronic devices. The low-temperature firing NiCuZn ferrites and Fe-based alloy powders for inductors have attracted much attention in recent years, while the review of the materials and processes for multilayer power inductors has not been described in the open literature to our best knowledge. Therefore, this article is aimed to deliver an overview on the progress of the multilayer power inductors, from materials and processes' point of view.

Purpose The interaction between the silver powder and organic vehicle largely determines the rheological behavior of silver conductive paste. This study aims to prepare silver conductive paste with an organic vehicle system consisting of ethyl cellulose (EC) and terpineol/butyl carbitol acetate solvent mixtures. The study also aims to measure the rheological behaviors of the silver conductive pastes with different solvent mixtures, EC molecular weights and silver content, to investigate the interaction among the polymer, solvent and silver powder and determine the main factors affecting the thixotropic index and maximum silver content. Design/methodology/approach The rheological behaviors of silver conductive pastes with different solvent mixtures, EC molecular weights and silver content were investigated using viscometer. Findings The shear thinning became significant with increasing EC molecular weight. The EC solvation with higher molecular weight in solvent is better than that of EC with lower molecular weight. This leads to a stronger interaction between the silver powder and EC with higher molecular weight and consequently good silver particle dispersion. The relative viscosity of silver conductive paste at 10 s−1 increases significantly with increasing silver content, but the relative viscosity at 100 s−1 is much less sensitive to the silver content. The viscosities at low and high shear rate can be increased by increasing the silver content and EC molecular weight, respectively. Originality/value The interaction among the polymer, solvent and silver powder was investigated for the silver paste with high solid content. The main factors affecting the viscosities at high and low shear rates, thixotropic index and maximum silver content were determined.

A schematic representation of the defect chemistry in ZCM-SCNT and ZCM-SCO.

Because used LiFePO4 batteries contain no precious metals, converting the lithium iron phosphate cathode into recycled materials (Li2CO3, Fe, P) provides no economic benefits. Thus, few researchers are willing to recycle them. As a result, environmental sustainability can be achieved if the cathode material of spent lithium-iron phosphate batteries can be directly reused via electrochemical technology. Lithium iron phosphate films were developed in this study through electrophoretic deposition using spent lithium-iron phosphate cathodes as raw materials to serve as lithium-ion sieves. The lithium iron phosphate films were then coated with a layer of polypyrrole (PPy) conductive polymer to improve the electrochemical properties and the lithium-ion adsorption capacity for brine. Cyclic voltammetry, charge/discharge testing, and an AC impedance test were used to determine the electrochemical properties and lithium-ion adsorption capacity of lithium-ion sieves. The findings indicate that lithium iron phosphate films prepared from spent LiFePO4 cathodes have a high potential as a lithium-ion sieve for electro-sorption from brine.

Yttria-stabilized tetragonal zirconia (YTZP) ceramics with high densification and superior mechanical properties were obtained using gel casting technology and a two-stage sintering process. Well-dispersed Nano-sized (94 nm) zirconia slurry with high solid content (45vol%) was prepared for gel casting using Dolapix CE64 as the dispersant. As the dispersed slurry was added epoxy monomer (EGDGE) and polymerization initiator (DPTA), Dolapix CE64 promoted gelling, leading to an abrupt increase in the slurry viscosity. As Dolapix CE64 was added into the slurry, its functional carboxyl groups reacted with EGDGE, resulting in a decrease in gelling incubation time and an increase in viscosity, hence, leading to gel casting failure. The addition of hydroquinone (HQ) into the slurry can be used to delay the polymerization and extend the gel casting working time. After gel casting, the temperature was raised to above 60o C to promote the polymerization, leading to an increase in the green strength.A two-stage sintering process was used to control the grain growth. The first stage sintering temperature was chosen at 1300oC, where the relative density reached 83%. In the second sintering stage, the temperature was lowered to 1240°C and soaked for 24 h to inhibit grain growth (mean grain size of 195 nm) and continue densification to a relative density of above 99%. Vickers hardness of 15.2GPa, fracture toughness of 7.8MPa.m1/2, and flexural strength of 771MPa can be obtained for the sample prepared using gel casting technology with a two-stage sintering process.

A screen printing process was used to substitute dry molding to solve the uneven compaction problem in the coil center column during molding in this study. FeSiCr alloy powders (FSC) with a large particle size were mixed with fine spherical carbonyl iron powder to increase the compaction density. FSC to carbonyl iron powder (CIP) mixing ratio effects on magnetic paste rheological behaviors and magnetic properties of the molding coil prepared using screen printing were investigated. A magnetic paste with the lowest viscosity can be obtained using 3C7F (30% CIP + 70% FSC) due to the small-sized CIP adsorbed onto the FSC surface. This process reduces the interlocked network formation resulting from the CIP. The toroidal core with 3C7F exhibited the highest relative density and highest inductance. The coils with pure CIP and higher CIP content exhibited the better DC superposition characteristic. The toroidal core loss increased rapidly as the FSC content was increased. A proper trade-off between the inductance, DC-bias superposition characteristic, and magnetic core loss can be reached by choosing a suitable powder mixing ratio.

Multilayer Fe–Si–Cr alloy chip power inductors have the benefits of a smaller, thinner profile, lower DC resistance and higher rated current. During metal multilayer power inductor co-firing, Fe–Si–Cr alloy powders react with the inner electrode, silver, to form a large amount of hexagonal flaky AgCrO2. The p-type semiconductor, AgCrO2, will cause co-fired Fe–Si–Cr alloy multilayer chip power inductor insulation degradation, hence reducing the power conversion efficiency due to the increase in eddy current loss. The AgCrO2 forming mechanism is investigated in this study. It was observed that silver reacts with the Fe–Si–Cr thermal grown oxide layer, Cr2O3, and subsequently leads to the formation of Ag2CrO4 when the temperature is lower than 650 °C. The formed Ag2CrO4 with low melting temperature then volatilizes at higher temperatures through the pore channels to react with the volatilized Cr2O3 to form the AgCrO2. AgCrO2 will cause Fe–Si–Cr alloy multilayer chip inductor resistivity and breakdown voltage degradation.

This research is aimed toward an understanding of the effects of the chemical characteristics and mineral compositions of sandstone and formation water based on saline water-rock-supercritical CO2 interaction simulation experiments. These experiments were conducted to assess whether toxic trace elements could be dissolved and released in formation water from sandstone in a CO2 storage layer after CO2 geological sequestration, thus affecting groundwater quality. The experimental results reveal that the concentrations of Cd and Pb in the water under examination exceeded the national primary drinking standard as a result of saline/fresh water-rock-supercritical CO2 interactions after 40 d of sandstone immersion in saline/fresh water and 20 d of interaction. In addition, the Mn concentration in the saline/fresh water exceeded the national secondary drinking standard after 40 d of sandstone immersion and 20–80 d of interaction. However, Cd, Pb, and Mn were released to a greater extent (in terms of concentration, 2-fold for Cd, 7-fold for Pb, and 1.7-fold for Mn) in the presence of salinity, revealing that salinity may enhance the dissolution of Cd, Pb, and Mn after 20 d of saline water-rock-scCO2 interaction. After a long period of supercritical CO2-sandstone interaction, the trace metals previously mobilized can be immobilized again by an increase in alkalinity due to aragonite dissolution.

In this study, amorphous FeSiCrB alloy powder, carbonyl iron powder, and high-temperature heat-resistant silicone resin were used to prepare power molding inductors, and the effects of different heat treatment procedures on the magnetic properties were investigated. Two heat treatment procedures were used. Procedure 1: Amorphous FeSiCrB alloy powder was pre-heat-treated, then mixed with carbonyl iron powder and silicone resin and uniaxially pressed to prepare power inductors. Procedure 2: A mixture of amorphous FeSiCrB alloy powder, carbonyl iron powder, and silicone resin was uniaxially pressed. After dry pressing, the compacted body was heat-treated at 500 °C. Heat treatment after compaction can reduce the internal strain caused by high-pressure compaction and promote the crystallization of superparamagnetic nano-grains simultaneously. Therefore, the compacted sample after heat treatment exhibited better magnetic properties.

Flaws, such as porous structure and small grains easily occur during Cu(In,Ga)Se2 (CIGS) thin film absorber preparation from nanocrystallites have been the major obstacle to practical application of this technology. The selenization process parameter effects on the densification, microstructure, and electrical properties were investigated in this study using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and Hall-effect analyzer. Grain size was observed nearly independent of the selenization time but increased with increasing selenium mass in the graphite box for selenized CIGS film at 500 °C. Pre-sintering at 2 bar N2 atmosphere overpressure can effectively suppress the in-plane tensile stress generated by the shrinkage mismatch between the CIGS and Mo-coated glass substrate during 500 °C sintering, leading to better densification. The pre-sintered and selenized CIGS film exhibited good electrical properties suitable for solar cell applications.

Magnetic components prepared using Fe–Si–Cr alloy powders have been widely used in high-current power inductors due to their high initial permeability, high-saturation magnetization, and excellent dc-bias characteristics. Fe–Si–Cr alloy bodies were prepared in this paper using a uniaxial molding press at different compaction pressures. Samples were then annealed at different temperatures to form a chromium-rich oxide insulating layer on the powder surface to reduce the core loss. The compaction pressure and the annealing temperature effects on the microstructure, internal strain, and insulating layer thickness and the electromagnetic properties for Fe–Si–Cr alloy powder compacts were investigated. The results showed that the relative density gradually increased with increasing compaction pressure, leading to increased saturation magnetization, thereby improving the initial permeability from 29 to 37. After annealing, the internal strain was reduced, which resulted in the initial permeability increasing substantially. Moreover, the electric resistivity and dc-superposition characteristics also increased with increasing heat treatment temperature. However, excessively thick insulating layer formed on the Fe–Si–Cr alloy powder surface resulting from annealing at too high temperature leading to initial permeability and saturation magnetization degradation.

This study investigates the electric and magnetic properties of multilayer inductors made of FeSiCr alloy powders sintered at different temperatures and atmospheres. For FeSiCr alloy sintered in air, the semiconducting AgCrO2 phase formation has a great impact on the insulation resistance and withstands pulse voltage. The inductance for samples sintered in the air decreased with increasing sintering temperature. The insulation resistances were low for the samples sintered under a nitrogen atmosphere. However, re-annealing treatment in the air can increase insulation resistance. The inductance sequence for samples sintered under nitrogen atmosphere is 750 °C > 650 °C > 850 °C. Multilayer FeSiCr alloy inductors can be sintered under a nitrogen atmosphere to increase the inductance by suppressing nonmagnetic phase formation and improve the Q value by increasing the silver conductor continuity. After sintering, multilayer inductors can be re-annealed in the air to increase the resistance, and hence increase the ability to withstand pulse voltage.

It is difficult to achieve homogeneous phosphatized iron powder dispersion in organic resins during the preparation of soft magnetic composites (SMCs). Inhomogeneous iron powder mixing in organic resins generally leads to the formation of micro-structural defects in SMCs and hence causes the magnetic properties to become worse. Phosphatized iron powder dispersion in organic resins can be improved by coating the phosphatized iron powder surfaces with a coupling agent. This study investigated the (3-aminopropyl) triethoxysilane (APTES) surface modification effects on the electromagnetic properties of phosphatized iron-based soft magnetic composites (SMCs). The results showed that the phosphatized iron powder surface can be modified using APTES to improve the phosphatized iron powder and epoxy resin compatibility and hence enhance phosphate iron powder epoxy mixing. The tensile strength, initial permeability, rated current under DC-bias superposition and magnetic loss in SMCs prepared using phosphatized iron powders can be effectively improved using APTES surface modification, which provides a promising candidate for power chip inductor applications.

The phosphoric acid addition effect on phosphate insulation coating microstructure was investigated in this study. The relationships between the phosphate insulation coating microstructure and temperature resistance, corrosion resistance and magnetic properties of iron-based soft magnetic composites (SMCs) were studied by using SEM, TEM/EDS and FTIR. It was observed that an iron phosphate/carbonyl iron core/shell structure is formed with carbonyl iron powder after phosphatizing treatment. The iron phosphate phase was identified as amorphous and its thickness increased from 30 nm to 60 nm as the phosphoric acid concentration was increased from 1 wt% to 2 wt%. When the phosphoric acid concentration was further increased to 5 wt%, the excess iron phosphate precipitates between the soft magnetic composite particles. The temperature and corrosion resistance and resistivity of the iron-based SMCs can be effectively improved using carbonyl iron powders after phosphatizing. The initial permeability of the iron-based SMCs decreased with increasing phosphoric acid concentration due to thicker insulation layer formation. However, the imaginary permeability below the domain wall displacement resonance frequency decreased with increasing phosphoric acid concentration. The DC-bias superposition characteristic can also be improved by increasing the phosphoric acid concentration. Iron-based SMCs with superior temperature and corrosion resistance, initial permeability, magnetic loss and DC-bias superposition characteristics can be obtained by controlling the phosphoric acid concentration during phosphatizing to adjust the iron phosphate precipitate thickness on the iron powder surface.

Nearly dispersed marcasite CuSe 2 (m-CuSe 2 ) and berzelianite Cu 2 Se (b-CuSe 2 ) crystals were successfully synthesized using copper and selenium-triethylene glycol (TEG) solution thermal decomposition using triethylenetetramine (TETA) as the reducing agent and polyvinylpyrrolidone (PVP) as the capping agent. The crystalline structure, electronic and copper selenide particles optical characterization were investigated using X-ray diffractometer (XRD), Scanning electron microscopy (SEM), Transmission electron microscopy (TEM), X-ray photoelectron spectroscopy (XPS) and UV–vis absorbance spectra. The TETA addition effects on crystal phase development and morphology were investigated. The obtained copper selenides are m-CuSe 2 and b-CuSe 2 for the samples added with TETA of 0.007 M and 0.147 M, respectively. The measured energy gaps for m-CuSe 2 and b-CuSe 2 are 1.49 eV and 1.98 eV, respectively. The marcasite CuSe 2 can be obtained by annealing krutaite CuSe 2 at a higher temperature.

A planar inductor with excellent magnetic characteristics was successfully prepared by screen printing high solid content iron-based alloy magnetic pastes onto copper-clad laminates (CCL). The sample was then cold-isostatic pressed (CIP) to increase the packing density. To solve the problems of low electrical resistivity and low power handling capability of alloy powders for power inductor applications, an epoxy resin vehicle was added to form an insulating layer on top of the iron-based alloy powder surfaces and distribution gaps between the alloy powders. A central column was formed by punching in the center of the planar inductor and filled with magnetic paste to increase the inductance, magnetic flux channeling, and storage energy. A planar inductor 8.5 mm×7.0 mm×0.4 mm in size with an inductance value of about 2.7μH at 1 MHz, a quality factor of 10 to 13, and inductance decline rate of about 5% at a DC bias of 2.5 A can be successfully prepared using the proposed method. A 3D electromagnetic field finite element analysis tool (ANSYS Maxwell R19.3) was used to simulate the coil geometry and magnetic paste formulation effects on the magnetic flux density distribution, and the planar inductor electromagnetic properties to identify the optimal parameters. The differences between the simulation and the experimental planar inductor DC-bias superposition characteristics were compared. The deviations between the measured and simulated results are only within 6%, suggesting that the simulation has very high accuracy and reliability.