Multifunctional FeSiAl Soft Magnetic Composites with Inorganic-Organic Hybrid Insulating Layers for High Mechanical Strength, Low Core Loss and Comprehensive Anti-Corrosion

Excellent soft magnetic performance, superior mechanical strength and good corrosion resistance ensures that soft magnetic composites can be applied in practice for a long time. It is difficult for single organic coating or inorganic coating to meet the multifunctional requirements of a high-performance magnetic core. In this work, inorganic-organic hybrid insulating layers have been designed, which integrates the complementarity of the single type of insulating materials. After 700 degrees C annealing, FeSiAl cores (outer diameter x inner diameter x height= 33.02 x 19.94 x 10.67 mm) deliver a core loss as low as 118.9 mW/cm(3) and effective permeability as high as 61.6 at 50 mT and 100 kHz, which is due to the synergistic insulation of the SiO2 layer, TiO2 layer and SiO2-TiO2 hybrid layer on the surface of FeSiAl powder. Furthermore, crush strength is up to 1012.5 N, which may be ascribed to the SiO2-TiO2 hybrid layer. FeSiAl cores display excellent corrosion resistance activity with a maximum polarization resistance of 25,830.86 omega cm(-2). The inorganic-organic hybrid insulating layer has implications for obtaining soft magnetic powder cores with high mechanical strength, low core loss and good corrosion resistance.

Automated summary

The study introduces an inorganic-organic hybrid insulating layer designed for FeSiAl powder, resulting in excellent soft magnetic performance, mechanical strength, and corrosion resistance.