ABSTRACT To optimize cost and weight and streamline the manufacturing process of existing soft magnetic components, which currently rely on metallic soft magnetic particles, an innovative approach involving the preparation of high-performance magnetic polymeric composites is proposed. These composites are based on soft magnetic ferrite particles with high Curie temperature and magnetic saturation, along with low coercivity and remanent magnetization, and are used as fillers in thermoplastic polymers. To achieve these goals, cobalt ferrite (CoFe2O4) micro- and nanoparticles were synthesized by two different methos: solid-state reaction and coprecipitation. The as-obtained particles were used to fabricate soft magnetic polymer composites by extrusion and injection molding methods. The successful synthesis of cobalt ferrite was confirmed by X-ray diffraction, Fourier transform infrared spectroscopy (FTIR), and Raman spectroscopy. The magnetic behavior of cobalt ferrites and polymer composites was also investigated by vibrating sample magnetometry (VSM). This study shows that these new high-performance soft magnetic polymer composites can be used as alternative materials for the manufacture of magnetic components such as inductors and transformers and that their low cost and lightweight make them suitable for the manufacture of magnetic components.
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