Soft Ferrites Research Articles

Study on microstructure characteristics and hole expansion mechanism of Ti-Nb-V microalloyed 900 MPa hot-rolled ferrite-bainite high hole expansion steel

In this study, a 900 MPa grade hot-rolled ferrite/bainite high hole expansion steel was developed using thermomechanical controlled processing (TMCP) and medium-temperature coiling with a Ti-Nb-V multi-microalloy design. The effects of cooling rates and coiling temperatures on the microstructure, mechanical properties, and hole expansion behavior were systematically investigated. The steel, coiled at 600°C and cooled at a controlled rate (10-25°C/s), demonstrated an excellent balance of strength and ductility, achieving a tensile strength of 901 MPa and elongation of 23%. The microstructure consisted of approximately 62% ferrite and 38% bainite, characterized by a uniform and fine grain distribution. The high coiling temperature increased the content of Ti-Nb-V composite precipitates, while reduced cooling times promoted the formation of smaller precipitates primarily along dislocation lines and grain boundaries. A hole expansion ratio of 77% was achieved due to the optimized grain morphology and phase ratio, with refined grains and high-angle grain boundaries impeding crack propagation. Additionally, the increased presence of secondary precipitates strengthened the soft phase ferrite and enhanced the coordinated deformation between ferrite and bainite. These combined effects significantly improved the steel's resistance to crack propagation during hole expansion, making it a promising material for applications requiring high strength and formability.

Tailoring magnetism in chromium-doped zinc cobalt ferrite nanostructure for advanced spintronic memory devices

Soft magnetic ferrites serve as a crucial component in a wide array of sensing and actuating applications across various industries, including consumer electronics, automotive systems, spintronics, and more. These materials also find utility in spintronics, particularly for next-generation magnetic random-access memory (MRAM) due to their excellent inductive properties, which enhance the performance and scalability of spintronic memory devices. This study focuses on fine-tuning soft magnetic ferrites for inductive applications by doping them with Cr ions. By utilizing advanced experimental techniques such as the vibrating sample magnetometer (VSM) for bulk magnetometry and X-ray magnetic circular dichroism (XMCD) alongside X-ray absorption spectroscopy for atomic studies, the research aims to investigate the structural, electronic, and magnetic properties of the nanoferrites. Addition of doping in the soft ferrites observes reduction in the general magnetic parameters, with the only exception being coercivity, which decreases from 381 Oe to 275 Oe as the doping concentration increases from x = 0 to x = 0.02, and then increases to 350 Oe at x = 0.03. Through such precise tuning of the nanoparticles, this study aims to investigate the controllable soft magnetic properties of the nanoferrites, thereby paving the way for fast access times, non-volatility, and low energy consumption, presenting a compelling alternative to conventional memory technologies.

Exploring the effect of exchange coupling in (SrFe9.8Al2La0.2O19)1-x/(Co0.7Zn0.3Fe2O4)x nanocomposites synthesised by sol–gel auto combustion method

Extensive research has been conducted over the last decade to develop permanent magnets utilizing less rare earth materials. Exchange-coupled nanocomposite magnets are a fascinating development in the field of permanent magnets. They involve the combination of hard and soft ferrites, resulting in a unique and evolving magnet. Here we present an in-depth structural, morphological and magnetic characterization of ferrite-based nanostructures obtained through a bottom-up sol−gel approach. The combination of high coercivity of a hard phase SrFe9.8Al2La0.2O19 (SFALO) and high saturation magnetization of a soft phase, Co0.7Zn0.3Fe2O4 (CZFO), allowed us to develop exchange-coupled bi-magnetic nanocomposites by varying the mass percentage (x = 0, 0.1, 0.2, 0.3, 0.4, 1). Thermogravimetric analysis (TGA) up to 1200 °C was used to investigate the material’s thermal properties with the phase formation temperature. Detailed atomic/nano-scale structural characterizations of these nanocomposites were performed by X-ray diffraction and Transmission Electron Microscopy. The average particle size was calculated from the SEM analysis and it was observed that most of the composites with ratio x = 0.1, 0.3 & 0.4 was 145 nm and x = 0.2 was 165 nm. The Switching Field Distribution (SFD) curve revealed the exchange coupling between soft and hard magnetic particles. The findings indicate that the inclusion of a soft magnetic phase has a considerable impact on the exchange coupling between the hard and soft ferrite phases. As the spinel concentration increased, in the composite the saturation magnetization increased from 18 emu/g to 48 emu/g. From the stroner-wholfrathmodel, the decrease in the remanence ratio below 0.5 concludes the crystallites are randomly oriented. The nanocomposite with the ratio x = 0.1 was observed with the high magneto crystalline anisotropy of 2183.23 × 102 (J/m3) and a high energy product (BH)max of 5.5 kJ/m3. The aforementioned features of nanocomposites demonstrate their potential for use in permanent magnet applications.

Transverse crack micromechanisms in high-strength steel weld metal with microstructure heterogeneity under hydrogen-containing environment

The transverse crack susceptibility for high-strength steel weld metal with microstructure heterogeneity was investigated under various environment. Transverse cracking probability (C%) increases with increasing microstructure heterogeneity and diffusible hydrogen content. The dominant transverse crack initiation are soft massive pre-eutectic ferrite (PF), the deformation-uncoordinated acicular ferrite (AF)-PF interface and inclusions aggregation. PF, AF-PF interface and inclusions acts as the principal crack extension channel during crack propagation. Transverse cracks pass AF mainly extend along {100} plane while only along {110} when passing PF. MAGBs and HAGBs impede crack propagation. The Ʃ3 boundaries promote the crack propagation, while Ʃ11, Ʃ13b and Ʃ17b hinder the crack propagation. The transverse crack of weld metal under hydrogen-containing environment is attributed to the combination of HEDE and HELP mechanisms in the presence of microstructure heterogeneity and inclusions.

Interface Structures on Mechanically Polished Surface of Spinel Ferrite and Its Effect on the Magnetic Domains.

Soft magnetic spinel ferrites are indispensable parts in devices such as transformers and inductors. Mechanical surface processing is a necessary step to realize certain shapes and surface roughness in producing the ferrite but also has a negative effect on the magnetic properties of the ferrite. In the past few years, a new surface layer was always believed to form during the mechanical surface processing, but the change of atomic structure on the surface and its effect on the magnetic structure remain unclear. Herein, an interface structure consisting of a rock-salt sublayer, distorted NiFe2O4 sublayer, and pristine NiFe2O4 was found to form on mechanically polished single-crystal NiFe2O4 ferrite. Such an interface structure is produced by phase transformation and lattice distortion induced by the mechanical processing. The magnetic domain observation and electrical property measurement also indicate that the magnetic and electrical anisotropy are both enhanced by the interface structure. This work provides deep insight into the surface structure evolution of spinel ferrite by mechanical processing.

Investigating the influence of cerium doping on the structural, optical and electrical properties of ZnNiMgFe2-xCexO4 soft ferrites

The present work reports the optical, structural, and electrical properties of cerium-doped Zn0.6Ni0.2Mg0.2Fe2-xCexO4 soft ferrites by green synthesis method that unwrap transformative insights and find technological applications through X-ray diffraction (XRD), UV visible spectroscopy and IV-point probe techniques. Ferrites with different cerium concentrations (x = 0.0, 0.0250, 0.0375) show an enormous difference in the optical, structural, and electrical behavior of the ferrites. The crystallite size increases to 46.9 nm, with a concomitant increase in lattice constants up to 8.550 Å for x = 0.0375. A similar structural shift was noticed in X-ray and bulk densities from 5.031 to 4.982 g/cm³ and 3.83 to 3.97 g/cm³, respectively. The optical explorations revealed a remarkable bandgap reduction from 2.768 eV to 2.758 eV improving the utility of the material substantially in magneto-optic devices. Conversely, the refractive index increases from 2.420 to 2.423, and the imaginary dielectric constant goes up from 10.654 to 10.667, giving a herald of advancement in photonic technologies. Electrically, the study marks a drastic reduction in DC resistivity from 1.95 × 105 to 6.13 × 103 ohm-cm with the Ce doping, which indicates higher conductivity suitable for telecommunication. This extensive work on Ce-doped soft ferrites now opens up newer avenues of applications in electronics and magneto-optics, blending scientific inquiry with practical utility.

Experimental Study on the Preparation of High-Purity Iron Oxide Red by Acid Leaching Iron from Coal Gangue.

Aiming at the problems of the large storage, complex composition, low comprehensive utilization rate, and high environmental impact of coal gangue, this paper carried out experimental research on the preparation of iron oxide red from high-iron gangue by calcination activation, acid leaching, extraction, and the hydrothermal synthesis of coal gangue. The experimental results show that when the calcination temperature of coal gangue is 500 °C, the calcination time is 1.5 h, the optimal concentration of iron removal is 6 mol/L, the acid leaching temperature is 80 °C, the acid leaching time is 1 h, and the liquid--solid mass ratio is 4:1; the iron dissolution rate can reach 87.64%. A solvent extraction method (TBP-SK-hydrochloric acid system) was used to extract the leachate, and a solution with iron content up to 99.21% was obtained. By controlling the optimum hydrothermal conditions (pH = 9, temperature 170 °C, reaction time 5 h), high-purity iron oxide red product can be prepared; the yield is 80.07%. The red iron oxide was characterized by XRD, SEM-EDS, particle-size analysis, and ICP-OES. The results show that the red iron oxide peak has a cubic microstructure, an average particle size of 167.16 μm, and a purity of 99.16%. The quality of the prepared iron oxide red product meets the requirement of 98.5% of the "YHT4 Iron oxide Standard for ferrite". It can be used as a raw material to produce high-performance soft magnetic ferrite. In summary, this experimental study on the preparation of iron oxide red from coal gangue is of great significance for the comprehensive utilization of coal gangue to realize the sustainable development of the environment and economy.

Synthesis, characterization and microwave absorption properties of BaFe12O19/Ni0.5Mn0.5Fe2O4@ polyaniline nanocomposites with different ferrite percentages

AbstractIn this paper, BaFe12O19/Ni0.5Mn0.5Fe2O4@PANI core‐shell nanocomposites were synthesized with different ferrite/PANI ratios. The Ferrite nanoparticles were prepared by the auto‐combustion sol–gel method. Chemical oxidative polymerization of aniline in acidic solution along with adding ferrite nanoparticles to the composition was used for the synthesis of nanocomposites. The product then was studied by X‐ray diffractometer)XRD(, field emission scanning electron microscope (FE‐SEM), transmission electron microscope (TEM), and Fourier transform infrared spectroscopy (FTIR) analyses. The magnetic properties of samples were investigated with vibrating sample magnetometer (VSM). Also, nanocomposite samples were examined in terms of the ability to absorb microwaves. Using Vector Network Analyzer (VNA). the reflection loss (RL) of nanocomposites was measured at frequencies between 2 and 18 GHz. The minimum reflection loss (RLmin) was obtained at −36.98 dB at the frequency of 13.8 GHz with an effective absorption bandwidth of 4.87 GHz for the sample with the equal ratio of ferrite/PANI. Synthesized nanocomposite as an effective compound has very high reflection loss in a wide frequency range.Highlights Thermal stability is improved by adding ferrite nanoparticles to polyaniline. The polymer shell reduces the magnetic properties of ferrite nanoparticles. There is a strong exchange coupling between hard and soft ferrite. Ferrite/polymer ratio of 1:1 has the lowest amount of reflection loss. In the X and Ku band, magnetic loss is mainly caused by eddy currents.

Comprehensive structural, optical, electrical, dielectric and magnetic analysis of co-precipitated Mg-Zn-Cu-Ce soft ferrites

The Mg0.6Zn0.2Cu0.2Fe2-xCexO4 series (0.0, 0.0125, 0.0250 and 0.0375) was prepared by coprecipitation and characterized by X-ray diffraction (XRD), UV–vis, Fourier transform infrared spectroscopy (FTIR), current and voltage (I-V), an LCR meter and a vibrating sample magnetometer (VSM). XRD analysis revealed a cubical structure with crystallite sizes ranging from 37.42 to 19.20 nm and lattice constants varying between 8.3938 and 8.4301 Å. Absorption bands, i.e., octahedral bands (533.87 – 533.99 cm−1) and tetrahedral bands (420.73 – 415.96 cm−1), were detected to confirm the occurrence of metal oxides. The ranges of the optical band gap energy (Eg = 2.782 – 2.756 eV) and DC resistivity (ρDC = 5.309 × 109 Ohm.cm to 2.071 × 1010 Ohm.cm) revealed the semiconducting nature of the composed ferrites. The dielectric constant and loss, AC conductivity and impedance were determined, and sample Mg0.6Zn0.2Cu0.2Fe0.0125Ce1.9875O4 exhibited the highest dielectric constant. The saturation magnetization (Ms = 12.7625 – 21.9460 emu/g) and remanence (Mr = 8.5460 – 15.6781 emu/g) increased, while the coercivity (Hc = 796.76 – 660.91 Oe) decreased. The determined values of the microwave frequency “ωm” indicate that ferrites are applicable in wireless communication systems.

A remarkable permeability enhancement of Ni1−xZnxFe2O4 (x = 0.65 and 0.70), using a multi-compound calcined additive

In this study, entanglement of composition, additive and/or sintering conditions and their effects on magnetic properties of soft ferrites, nickel zinc spinel ferrites (Ni1−xZnxFe2O4, x = 0.65 and 0.70) which were prepared via conventional solid-state reaction method investigated. Also an equiponderant calcined mixture of Bi2O3, CaO, CeO2, SiO2, Al2O3, Y2O3 and nanotitania was mixed thoroughly and used as a multi-compound calcined additive (MCCA). Calcined ferrite powders were crushed, dry and wet milled, dried, mixed with different amounts of MCCA (0.0, 0.5, 1.0, 1.5 and 2.0 wt%), formed in toroidal shapes and finally sintered at different temperatures, from 1150 up to 1360 °C for 3 h. X-ray diffraction assessment confirmed formation of the single phase cubic spinel structures. Initial permeability and Q-factor spectra of the toroids were obtained from 0.1 to 1000 kHz, using an LCR meter. The results show that initial permeability of each sample has a maximum and addition of MCCA to the ferrites leads to a marvelous increase in permeabilities. Additionally, MCCA decreases the optimum sintering temperature too. The optimum amounts of additive were 1.0 and 0.5 wt% for the x = 0.65 (μ′ = 492, Ts = 1280 °C) and x = 0.70 (μ′ = 478, Ts = 1320 °C), respectively. Permeability spectra illustrate that utility zone of the Ni0.35Zn0.65Fe2O4 and Ni0.3Zn0.7Fe2O4 are both less than 100 and 10 kHz, respectively. The results represent that there is a strong entanglement between composition, additive and/or sintering conditions. It can be concluded the MCCA added Ni0.35Zn0.65Fe2O4, is suitable for application in the switching power supplies.

Magnetic Material in Triboelectric Nanogenerators: A Review.

Nowadays, magnetic materials are also drawing considerable attention in the development of innovative energy converters such as triboelectric nanogenerators (TENGs), where the introduction of magnetic materials at the triboelectric interface not only significantly enhances the energy harvesting efficiency but also promotes TENG entry into the era of intelligence and multifunction. In this review, we begin from the basic operating principle of TENGs and then summarize the recent progress in applications of magnetic materials in the design of TENG magnetic materials by categorizing them into soft ferrites and amorphous and nanocrystalline alloys. While highlighting key role of magnetic materials in and future opportunities for improving their performance in energy conversion, we also discuss the most promising choices available today and describe emerging approaches to create even better magnetic TENGs and TENG-based sensors as far as intelligence and multifunctionality are concerned. In addition, the paper also discusses the integration of magnetic TENGs as a power source for third-party sensors and briefly explains the self-powered applications in a wide range of related fields. Finally, the paper discusses the challenges and prospects of magnetic TENGs.

Curtailing of Torque Ripples in Switched Reluctance Motor using Nano Soft Ferrite Rotor

Switched Reluctance motors (SRM) enthralled many researchers due to their coherent structure and sturdy design switched reluctance motors are, robust, reliable, fault tolerated, efficient, and maximum temperature resistant when compared to other conventional motors. The drift in the power electronic converters enhances the usage of SRM, stator and rotor consisting of projected inward and outward poles the gap between the stator and rotor causes harmonics which cause torque ripples which are deteriorating SRM drives. In this paper, a ferrite rotor is considered which is composed by the different material like nickel, manganese, copper, ferric, and aluminium by manoeuvring combustion of solution and gel method. By availing ferrite material magnetizing and demagnetizing can be done quickly which is essential for SRM rotor.

Enhancement of Cobalt Bismuth Nano-Ferrite via Heat Treatment to be Applied in High-Frequency and Antimicrobial Applications

Cobalt bismuth nano-ferrite (Co/Bi) with the chemical formula CoBi0.02Fe1.98O4 was produced using a simple flash auto-combustion method at three different temperatures: as-prepared, 600°C, and 800°C. A single-phase spinel structure was confirmed using X-ray diffraction, and the nano-scale morphology was examined using AFM (atomic force microscopy). Magnetic measurements demonstrated that increasing the annealing temperature increased the saturation magnetization Ms by 1.3 times. However, the coercivity Hc changed from semi-hard ferrite (as-prepared sample) to soft ferrite (Co/Bi nano-ferrite at 800°C) and reduced 10.7 times that of as-prepared nanoparticles. Therefore, the 800°C Co/Bi nano-ferrite with a low coercive field is recommended for transformers, recording heads, inductor cores, magnetic shielding, and microwave devices. The as-prepared sample and that at 600°C displayed super-high microwave frequency (SHF) in the X band in high-frequency applications calculated from magnetic measurement. The 800°C sample also has an extremely high microwave frequency in the Ku band, which is utilized in radar and satellite communications. Antimicrobial characterization showed that raising the annealing temperature increased the effectiveness of the samples against tested microorganisms. Thus, the samples under investigation are highly suggested for ultra-high microwave frequency applications and biological antibacterial nanomaterials.

Structure, magnetic, and electrodynamic properties of SrInxFe12‐xO4/Ni0.5Zn0.5Fe2O4 composites at low temperature

AbstractExchange‐coupled hard–soft bi‐magnetic ferrites can be used as isolators, microwave absorption materials, filters, hyperthermia materials, and biosensors with improved energy properties. The nanocomposites with the chemical composition SrInxFe12‐xO4/Ni0.5Zn05Fe2O4 (where x varies from 0.00 to 0.04) have the advantages of both materials: spinel and hexaferrite. The combination of Sr‐hexaferrate with spinel ferrite results in proximity effects, reversal of magnetization in two stages, and blocking temperatures that can be tuned in bi‐magnetic hard and soft ferrites. It was found an anomalius kink in the hysteresis loops and two peaks in the switching field distribution at x ≤ 0.02. The exchange interaction on the surfaces of hard and soft nanoparticles explains the behavior of the magnetic characteristics.

Probing the influence of V2O5 and SBZKN composite additives on the magnetic characteristics and power loss of low-temperature sintered NiCuZn ferrites

Soft magnetic ferrites with exceptional magnetic characteristics and low power loss are in continuous demand in both academia and industry. In this work, a series of Ni0.22Cu0.31Zn0.47Fe1.98O4 ferrites doped with 0.5 wt% V2O5 and different SiO2-B2O3-ZnO-K2CO3-Na2CO3 (SBZKN) contents were synthesized using a conventional solid-phase method under a low sintering temperature of 925 ℃. The crystal phase, density, microstructure, grain size distribution, magnetic characteristics and power loss of the NiCuZn ferrites were studies to elucidate the composition-structure-property relationship. The underlying mechanisms were also thoroughly analyzed. The results showed that all the samples had a single-crystalline phase and dense microstructure when sintered at 925 ℃. As the SBZKN content increased, the density, saturation magnetization (Ms), residual magnetization (Br), complex permeability and quality factor (Q factor) exhibited a varying trend that increased initially and then decreased, while the coercivity (Hc) and power loss (Pcv) showed the opposite trend. The highest values of density, Ms, Br, magnetic permeability and Q factor of NiCuZn ferrites, obtained at an SBZKN content of 0.3 wt%, were 5.121 g/cm3, 51.07 emu/g, 188.47 mT, 389.8 and 114.3, respectively, while the lowest Hc and Pcv were obtained. The analysis showed that these outstanding magnetic and power loss characteristics were attributed to the uniform distribution of grain size and densification of NiCuZn facilitated by V2O5 and SBZKN incorporation.

Vortex-based soft magnetic composite with ultrastable permeability up to gigahertz frequencies

Soft magnetic materials with stable permeability up to hundreds of megahertz (MHz) are urgently needed for integrated transformers and inductors, which are crucial in the more-than-Moore era. However, traditional frequency-stable soft magnetic ferrites suffer from low saturation magnetization and temperature instability, making them unsuitable for integrated circuits. Herein, we fabricate a frequency-stable soft magnetic composite featuring a magnetic vortex structure via cold-sintering, where ultrafine FeSiAl particles are magnetically isolated and covalently bonded by Al2SiO5/SiO2/Fe2(MoO4)3 multilayered heterostructure. This construction results in an ultrastable permeability of 13 up to 1 gigahertz (GHz), relatively large saturation magnetization of 105 Am2/kg and low coercivity of 48 A/m, which we ascribe to the elimination of domain walls associated with almost uniform single-vortex structures, as observed by Lorentz transmission electron microscopy and reconstructed by micromagnetic simulation. Moreover, the ultimate compressive strength has been simultaneously increased up to 337.1 MPa attributed to the epitaxially grown interfaces between particles. This study deepens our understanding on the characteristics of magnetic vortices and provides alternative concept for designing integrated magnetic devices.

High Curie temperature and high magnetization potential Fe2CoS alloy soft magnet

Developing soft magnets is attracting extensive research efforts for several device applications and other issues. Here, we investigate the finite temperature magnetic properties of the Fe2CoS alloy using first-principles density functional theory calculations and Monte Carlo simulations. Without a demagnetization factor, it exhibits semi-hard-magnetic properties at room temperature. For instance, it exhibits a coercivity of 290 mT, a magnetic anisotropy constant of 218 kJ/m3, and a magnetic hardness parameter of 0.3. By considering the demagnetization factor at 300 K, the coercivity, magnetic anisotropy constant, and hardness parameter are reduced to 1.5 mT, 0.7 kJ/m3, and 0.035. Besides, compared to ferrites soft magnets, the Fe2CoS alloy shows a high relative permeability of 10,000 and low energy loss of 0.16 Watt/kg. The curie temperature (940 K) and high saturation magnetization MS (1.49 T) of the Fe2CoS alloy are significantly higher than those of soft ferrites and Permalloy. Therefore, we propose that the Fe2CoS alloy can be used as a potential Fe-based soft magnet.

Exploring 3D printing with magnetic materials: Types, applications, progress, and challenges

3D printing, also known as additive manufacturing (AM), represents a rapidly evolving technological field capable of creating distinctive products with nearly any irregular shape, often unattainable using traditional techniques. Currently, the focus in 3D printing extends beyond polymer and metal structural materials, garnering increased attention towards functional materials. This review conducts an analysis of published data concerning the 3D printing of magnetic materials. The paper provides a concise overview of key AM technologies, encompassing vat photopolymerization, selective laser sintering, binder jetting, fused deposition modeling, direct ink writing, electron beam melting, directed energy deposition and laser powder bed fusion. Additionally, it covers magnetic materials currently utilized in AM, including hard magnetic Nd–Fe–B and Sm–Co alloys, hard and soft magnetic ferrites, and soft magnetic alloys such as permalloys and elect­rical steels. Presently, materials produced through 3D printing exhibit properties that often fall short compared to their counterparts fabricated using conventional methods. However, the distinct advantages of 3D printing, such as the fabrication of intricately shaped individual parts and reduced material wastage, are noteworthy. Efforts are underway to enhance the material properties. In specific instances, such as the application of metal-polymer composites, the magnetic properties of 3D-printed products generally align with those of traditional analogs. The review further delves into the primary fields where 3D printing of magnetic products finds application. Notably, it highlights promising areas, including the production of responsive soft robots with increased freedom of movement and magnets featu­ring optimized topology for generating highly homogeneous magnetic fields. Furthermore, the paper addresses the key challenges associated with 3D printing of magnetic products, offering potential approaches to mitigate them.

Soft ferrite 3D printing of magnetic couplers of inductive power transfer systems

AbstractTraditional soft ferrite manufacturing is limited to simple geometries and materials, while 3D printing offers greater flexibility for complex designs. Notably, soft ferrites are crucial for magnetic couplers (pads) in inductive power transfer (IPT) systems to achieve efficient wireless power transmission. The adoption of soft ferrite 3D printing in IPT systems could lead to significantly improved magnetic coupler design, yet research in this area is limited. Hence, the paper first makes a comprehensive comparison of the existing soft ferrite 3D printing methods to ascertain their suitability for magnetic couplers in IPT systems, and then proposes the binder jetting (BJT) as a potential 3D printing approach that could be appropriate for IPT magnetic coupler implementation being versatile, cost‐effective, and suitable for large‐scale manufacturing with high precision. This paper explores the suitability of BJT by 3D printing toroid cores with Mn–Zn ferrite powder under different sintering temperature profiles. Experimental results are presented to show that toroid cores can be 3D printed with high printing precision, mechanical strength, and a relative permeability of 10. This paper also highlights the impact of sintering temperature on 3D‐printed cores, the challenges, limitations, and future research directions of soft ferrite 3D printing for IPT magnetic couplers by the BJT method.

Developing Ni0.5Zn0.5Fe2O4 ferrite with controlled particle size and morphology through optimized processing conditions of low energy solid state reaction.

Soft magnetic materials, like Ni0.5Zn0.5Fe2O4, require high temperatures and regulated environments for their manufacture and processing, which can be highly energy intensive. These requirements therefore result in higher production costs and energy consumption. To address this issue, the development of composite materials based on soft magnetic ferrites has become a prominent research area. The type of particles and their size distribution, shape, and dispersion within the polymer matrix can be crucial for controlling the magnetic properties. In this context, and to reduce energy consumption, the parameters of solid-state reaction (such as calcination temperature, calcination time, and milling time) were optimized in this work to produce magnetic particles with suitable shape and size for filling a thermoplastic matrix. The impact of these parameters on phase purity, morphology, particle size, and magnetic properties was thoroughly evaluated. The results highlight that the sample synthesized at 1200 °C for 6 hours achieved an impressive saturation magnetization value of 80.07 emu g-1, showcasing exceptional magnetic performance.