Effect of Al2O3 Content on the High-Frequency Magnetic Properties of Fe-Si Soft Magnetic Composites Prepared by SPS

IF 2.8 4区工程技术 Q3 ENGINEERING, ELECTRICAL & ELECTRONIC

Journal of Electronic Materials Pub Date : 2026-08-05 DOI:10.1007/s11664-026-13088-2

Fugui Liu, Yupeng Chen, Changgeng Zhang, Zhiwei Lin, Yongjian Li, Kai Liu

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引用次数: 0

Abstract

Fe-Si soft magnetic composites (SMCs) typically suffer from deteriorated permeability stability and increased eddy-current loss under high-frequency operating conditions, which limits their application in advanced power electronics. In this work, Fe−6.5 wt.% Si SMCs coated with Al₂O₃ insulating layers were fabricated by high-energy ball milling followed by spark plasma sintering (SPS). The influence of Al₂O₃ content on the microstructure, electrical resistivity, and magnetic properties was systematically investigated over a frequency range below 500 kHz. The results show that the introduction of Al₂O₃ effectively enhances the electrical insulation between Fe-Si particles, leading to increased resistivity and reduced high-frequency core loss. Scanning electron microscopy (SEM) and energy-dispersive x-ray spectroscopy (EDS) line-scan results indicate that, as the Al₂O₃ content increases from 2.5 wt.% to 7.5 wt.%, the coating layer on the surface of Fe-Si particles evolves from incomplete coverage to a more continuous Al₂O₃ insulating coverage. This structural evolution is accompanied by improved permeability stability and a substantial reduction in magnetic loss. Among the investigated samples, the SMC containing 7.5 wt.% Al₂O₃ achieves the most favorable balance between permeability stability and core-loss reduction. The improved magnetic properties are mainly attributed to the enhanced interparticle insulation and the suppression of eddy-current effects provided by the Al₂O₃ coating. These results provide useful insights into the optimization of Fe-Si soft magnetic composites for high-frequency applications.

Graphical Abstract

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Al2O3含量对SPS制备的Fe-Si软磁复合材料高频磁性能的影响

Fe-Si软磁复合材料（SMCs）在高频工作条件下通常存在磁导率稳定性恶化和涡流损耗增加的问题，这限制了其在先进电力电子设备中的应用。采用高能球磨-火花等离子烧结（SPS）法制备了Fe−6.5 wt.% Si的SMCs，并包覆了Al2O3绝缘层。在低于500 kHz的频率范围内系统地研究了Al2O3含量对微观结构、电阻率和磁性能的影响。结果表明，Al2O3的引入有效地增强了Fe-Si颗粒之间的电绝缘性，提高了电阻率，降低了高频铁芯损耗。扫描电镜（SEM）和能谱分析（EDS）结果表明，随着Al2O3含量从2.5 wt.%增加到7.5 wt.%， Fe-Si颗粒表面的涂层由不完全覆盖演变为更连续的Al2O3绝缘覆盖。这种结构的演变伴随着磁导率稳定性的提高和磁损耗的大幅降低。在所研究的样品中，含有7.5 wt.% Al2O3的SMC在渗透率稳定性和减少岩心损失之间取得了最有利的平衡。磁性能的提高主要是由于Al2O3涂层增强了颗粒间绝缘性和抑制了涡流效应。这些结果为高频应用的铁硅软磁复合材料的优化提供了有用的见解。图形抽象

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来源期刊

Journal of Electronic Materials 工程技术-材料科学：综合

CiteScore

4.10

自引率

4.80%

发文量

693

审稿时长

3.8 months

期刊介绍： The Journal of Electronic Materials (JEM) reports monthly on the science and technology of electronic materials, while examining new applications for semiconductors, magnetic alloys, dielectrics, nanoscale materials, and photonic materials. The journal welcomes articles on methods for preparing and evaluating the chemical, physical, electronic, and optical properties of these materials. Specific areas of interest are materials for state-of-the-art transistors, nanotechnology, electronic packaging, detectors, emitters, metallization, superconductivity, and energy applications. Review papers on current topics enable individuals in the field of electronics to keep abreast of activities in areas peripheral to their own. JEM also selects papers from conferences such as the Electronic Materials Conference, the U.S. Workshop on the Physics and Chemistry of II-VI Materials, and the International Conference on Thermoelectrics. It benefits both specialists and non-specialists in the electronic materials field. A journal of The Minerals, Metals & Materials Society.