Abstract
Fe-Si-Al soft magnetic composites (SMCs) with different particle sizes were prepared. Good insulation quality was achieved for all samples. The influences of the particle size on permeability, direct-current bias (DC-bias) performance, and core loss for SMCs with the same insulation content and with the same permeability were investigated in detail. SMCs made of small particles were found to possess low core loss at high frequency and high maximum magnetic induction (Bm) and enhanced DC-bias performance. However, the variation of particle size has little effect on the anti-saturation ability and the core loss at low frequency and low Bm for SMCs with fixed permeability. Based on the analysis of SMCs’ density, volume resistivity, core loss, effective demagnetizing field and eddy current, particle size dependence of these magnetic parameters were reasonably explained. This study suggests that particle miniaturization is the development direction of SMCs for high-frequency and high-power applications.
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