Next-generation laminated nanocrystalline magnetic cores for high-frequency power electronics: enhancing magnetic properties and thermal stability

This study presents the development of next-generation laminated nanocrystalline magnetic cores designed for high-frequency power electronics, with a focus on enhancing magnetic performance and thermal stability. Fe-based amorphous alloy ribbons were used as the base material and subjected to optimized annealing treatments to induce controlled nanocrystallization. To suppress interlayer eddy currents and improve mechanical integrity, a spin-coating method was employed to incorporate nickel-zinc ferrite (NZF) nanoparticles, which were surface-modified using titanate coupling agents to enhance dispersion and thermal resistance.

The results demonstrate that optimized thermal treatment significantly reduces coercivity and improves saturation magnetization by promoting the formation of fine α-Fe(Si) nanocrystals. The incorporation of NZF nanoparticles further enhances high-frequency performance by increasing interlaminar resistivity and improving magnetic flux continuity. The fabricated laminated cores exhibit reduced core loss, improved inductance stability under DC bias, and extended resonant frequency range, indicating strong potential for integration into high-frequency inductors, transformers, and wireless power transfer systems. These findings provide a scalable and effective materials strategy for realizing compact, thermally stable, and energy-efficient magnetic components in next-generation power electronics.