Abstract
Fe1.82Si0.18@Al2O3 soft magnetic composites (SMCs) have been fabricated by NaOH oxidation combined with subsequent spark plasma sintering (SPS). The microstructure and generation mechanism of Fe3O4 coatings on the surface of FeSiAl powders have been investigated systematically. Effects of oxidation time on the magnetic properties also have been revealed. In addition, the displacement reaction between Fe3O4 and Al during SPS process results in the formation of Al2O3 insulation layer, leading to a remarkable variation of the magnetic performances of SMCs. The increased NaOH oxidation time had positive influences on the electrical resistivity, frequency stability of permeability and core loss. The saturation magnetization first decreases then increases with the increase of oxidation time. These above results indicate that the fabrication method in this paper creates a way to form Fe3O4 nanoparticles and Al2O3 insulation layer, which enhance the magnetic performance of FeSiAl SMCs and will facilitate the design of efficient magnets in the future.
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