High-performance ultra-thin SiO2 layer encapsulated FeSiAl soft magnetic composites for low-loss 100 kHz- 4 MHz power applications

IF 4.7 3区材料科学 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials Chemistry and Physics Pub Date : 2025-09-19 DOI:10.1016/j.matchemphys.2025.131581

Hanyu Yao, Tao Jing, Shuwei Ma, Xianguo Liu

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引用次数: 0

Abstract

Soft magnetic composites (SMCs) play a crucial role in inductors for new energy vehicles, for which remains challenges in maintaining high permeability and reducing loss at kHz-MHz frequences. As an oxide with high resistivity of 10¹⁵–10¹⁶ Ω cm, SiO₂ is promising for high-frequency applications due to its disordered nano-skeleton structure and ultra-stability, whereas FeSiAl is advantageous with approaching zero magneto-crystalline anisotropy and magnetostriction. Here, thin SiO₂ layer is covered FeSiAl powders with silane coupling agent (KH550) and tetraethyl orthosilicate (TEOS) using the sol-gel method, in which the thickness of layer is designed by varying the concentration of TEOS. The influence of SiO₂ layer on microstructure and magnetic properties of SMCs have been investigated. A thin SiO₂ layer can achieve synchronous reduction of eddy current loss and hysteresis loss while maintaining high permeability through electrical/magnetic isolation of FeSiAl powders. FeSiAl powders are uniformly coated with a ∼10 nm SiO₂ layer, endowing SMCs a high crush strength of 162 N, cut-off frequency of 68.48 MHz, a large magnetic permeability of 96.6 (@ 1 MHz), low power of 65.4 kW/m³ (50 mT, 100 kHz) and 260.4 kW/m³ (5 mT, 4 MHz). The comprehensive soft magnetic properties of the prepared FeSiAl/SiO₂ SMCs are superior to those reported in literatures, which would be potentially applied to high-performance inductors in 100 kHz- 4 MHz frequency ranges.

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高性能超薄SiO2层封装fesal软磁复合材料低损耗100 kHz- 4 MHz功率应用

软磁复合材料（SMCs）在新能源汽车电感中发挥着至关重要的作用，但在kHz-MHz频率下保持高磁导率和降低损耗仍然是一个挑战。SiO2具有1015-1016 Ω cm的高电阻率，其无序的纳米骨架结构和超稳定性使其在高频应用中具有很大的前景，而fesal具有接近于零的磁晶各向异性和磁致伸缩的优势。本文采用溶胶-凝胶法将硅烷偶联剂（KH550）和正硅酸四乙酯（TEOS）覆盖在fesal粉末上，通过改变TEOS的浓度来设计层厚。研究了SiO2对SMCs微观结构和磁性能的影响。通过对fesal粉末的电/磁隔离，薄SiO2层可以实现涡流损耗和磁滞损耗的同步降低，同时保持高磁导率。fesal粉末均匀地涂覆了一层~ 10 nm的SiO2层，赋予SMCs高抗压强度162 N，截止频率68.48 MHz，高磁导率96.6 (@ 1 MHz)，低功率65.4 kW/m3 （50 mT, 100 kHz）和260.4 kW/m3 （5 mT, 4 MHz）。制备的fesal /SiO2 SMCs的综合软磁性能优于文献报道，具有应用于100khz ~ 4mhz频率范围内的高性能电感的潜力。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Materials Chemistry and Physics 工程技术-材料科学：综合

CiteScore

8.70

自引率

4.30%

发文量

1515

审稿时长

69 days

期刊介绍： Materials Chemistry and Physics is devoted to short communications, full-length research papers and feature articles on interrelationships among structure, properties, processing and performance of materials. The Editors welcome manuscripts on thin films, surface and interface science, materials degradation and reliability, metallurgy, semiconductors and optoelectronic materials, fine ceramics, magnetics, superconductors, specialty polymers, nano-materials and composite materials.