Magnetic and structural properties of iron phosphate–phenolic soft magnetic composites

Abstract

This work focuses on the effect of phosphate modification on the magnetic and surface properties of iron–phenolic soft magnetic composite materials. Fourier transform infrared (FTIR) spectra, EDX analysis, distribution maps, X-ray diffraction pattern and density measurements show that the particles surface layer contains a thin layer of nanocrystalline/amorphous phosphate with high coverage of powders surface. Magnetic measurements show that phosphating treatment decreases the loss factor, imaginary part of permeability, increases the electrical resistivity and operating frequencies by decreasing the effective particle size. The operating frequency increases from 200 kHz for uncoated-powders samples to 1 MHz for phosphated-powders samples at optimum concentration. Phosphated iron powders that are covered by 0.7 wt% of phenolic resin exhibits lower magnetic loss and higher frequency stability. The minimum loss factor and maximum permeability at each frequency can be obtained for 0.01 g/ml orthophosphoric acid concentration in comparison with other concentrations including 0.005 and 0.04 g/ml.