Enhancing the Magnetic Core Properties of Ultra-Thin Flaky FeSiAl Alloy Powders Through High-Temperature Reduction Treatment

The surface properties of ultra-thin flaky FeSiAl alloy powders with a thickness of 0.65 μm were modified through a high-temperature reduction process. The original FeSiAl alloy powders exhibited an inherent outer layer primarily composed of FeO_x, SiAl_xO_y, and Al₂O₃. The reduction process involved the reduction of Fe³⁺ to metallic Fe through the use of H₂. During the pressing process of the magnetic core, the flaky FeSiAl alloy powders naturally formed a stack structure with the (100) orientation. Following the reduction treatment, the FeSiAl magnetic core demonstrated an effective permeability as high as 624 at 100 kHz, with a total loss of 108.8 mW/cm³ under maximal applied fields of 50 mT at 100 kHz. These results reveal that high-temperature reduction treatment and reduction in the thickness of flaky FeSiAl alloy powders play the significant role in further enhancing their magnetic core properties.