Abstract
Fe-Si soft magnetic composites (SMCs) coated with novel insulating-magnetic-insulating (IMI) layer were prepared via ball milling Fe-Si/γ-Fe2O3 powders and subsequent spark plasma sintering (SPS) process. We had investigated the formation mechanism of the IMI layer and optimized the microstructure and magnetic properties of the Fe-Si/IMI SMCs by adjusting the γ-Fe2O3 coating content. The analysis results showed that the ball milled Fe-Si/γ-Fe2O3 powders exhibited superior magnetic properties. And γ-Fe2O3 would react with Si and produced Fe2SiO4 with good insulation at the interface between γ-Fe2O3 coating layer and Fe-Si alloy particles during SPS process, which finally resulted in the formation of a novel three-shell structure of Fe2SiO4-γ-Fe2O3-γ-Fe2O3 (IMI) layer. By controlling the γ-Fe2O3 coating content from 0.0 wt% to 10.0 wt%, optimized performances such as very low core loss (23.34 mW/cm3 at 50 kHz), high quality factor (18.4) and saturation magnetization (188.3 emu/g), were obtained when the γ-Fe2O3 coating content is 5.0 wt%.
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