Soft magnetic composites are powder metal products under development as an alternative to 2D laminates in electric motor applications. The 3D design of SMCs offers greater energy efficiency but poses a challenge to maintain adequate strength properties required for application. Soft magnetic composites are fabricated through compaction and heat treatment of iron particles coated with insulated coating to form a dense compact. The soft magnetic properties of the compact are affected by the properties of the iron powder, density of compact as well as the efficacy of forming uniform thin insulating coating at the particle boundary. Additionally, the strength of the compact is also affected by the nature of the insulating boundary at the particle interfaces. We report a low temperature process that involves cold sintering phenomenon to densify and strengthen soft magnetic composites. Iron powders have been modified using a co-precipitation method that forms a hydrated copper/iron oxalate coating on individual iron particles. Warm compaction of the modified iron powders at 100°C resulted in a highly dense soft magnetic composite which demonstrated ~ 3x improvement in strength. The compacts can be further heat treated in air at higher temperatures to form high strength oxide coating iron based soft magnetic composites. Results of the AC and DC magnetic measurements of fabricated cold sintered toroid compacts made as a function of heat treatment temperature reveal that DC permeability increased with heat treatment temperature. Analysis of AC core loss data showed that hysteresis power losses dominated the performance at lower heat treatment temperatures (< 300°C) beyond which dynamic core losses significantly increased.
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