Magnetic properties regulation and loss contribution analysis for Fe-based amorphous powder cores doped with micron-sized FeSi powders.

• The FeSiBCCr amorphous powder cores annealed at 763 K for 0.5 h exhibit favorable magnetic properties. • The FeSiBCCr/FeSi compound powder cores doped with 12 wt% of FeSi powders show the best magnetic properties. • The inter-particle eddy current loss has almost no effect on the total energy loss of powder cores. • The sum of hysteresis loss and residual loss is likely to hit 90% of total energy loss. • The residual loss is proportional to frequency to the power of 1.509 ~ 1.760. The influences of annealing temperature and mass fraction of gas-atomized FeSi powders within a range of 0 ~ 16 wt% on the soft magnetic properties of Fe-based powder cores, prepared by cold compacting the mixture of the water-atomized FeSiBCCr amorphous powders with diameter of 23 ~ 75 μm and the FeSi powders with size below 13 μm, has been systematically investigated. Loss contribution analysis for the corresponding Fe-based compound powder cores was also conducted. The core–shell structure of magnetic powders was characterized using scanning electron microscopy, energy dispersive X-ray spectroscopy analysis, and fourier transform infrared spectroscopy. The inter- and intra-particle eddy current losses have a much less impact on the total energy loss as compared to the hysteresis loss and residual loss in the entire testing frequency range. The residual loss is frequency to the power of 1.509 ~ 1.760. As compared to the FeSiBCCr amorphous powder cores, the effective permeability was enhanced by 17.8% with no-degraded DC-bias property over 63.2% of percent permeability at an applied field of 7960 A/m, while the core loss was reduced by 11.1% for the Fe-based powder cores doped with 12 wt% of the micron-size FeSi powders annealed at 763 K for 0.5 h. The compound Fe-based powder cores with excellent magnetic properties could contribute to minimization of the electrical and electronics components with high efficiency in the high power application field. [ABSTRACT FROM AUTHOR]