Low core loss combined with high permeability for Fe-based amorphous powder cores produced by gas atomization powders

Abstract

Toroid-shaped Fe-based soft magnetic amorphous powder cores were prepared from Fe76Si9B10P5 (at.%) amorphous powder by gas atomization and subsequent cold pressing with epoxy resin as a binder and insulation. The influence of epoxy resin content and annealing temperature on the magnetic properties of the amorphous soft magnetic powder cores were analyzed. The core loss at a frequency of 100 kHz for the samples with 2 wt% epoxy resin and annealed at 480 °C for 1 h is evaluated to be less than 800 mW/cm3 under a maximum induction of 100 mT. Meanwhile, the cores also exhibit high permeability of 86 at a frequency up to 20 MHz. These results suggest that Fe-based amorphous powder cores provide great potential for expanding the application of high frequency electronic elements used in rectifiers, inverters, transformers and inductance, which requires soft magnetic cores with high saturation magnetization, high permeability, and low core loss.