Electromagnetic performance and microstructure of amorphous/Fe-Si soft magnetic composites
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摘要: 本文利用成分与粒径级配两种手段优化了Fe-Si系软磁复合材料的电磁特性，并探究了软磁性能与微观组织的关系。先采用不同粉末粒径的Fe-Si粉末级配，之后利用Fe-Si-B-C非晶粉部分替代粒径相当的Fe-Si粗粉，可以获得良好的综合电磁性能。所制备的非晶/Fe-Si软磁复合材料在1 MHz内均具备良好的频率稳定性。当非晶粉∶Fe-Si粗粉∶Fe-Si细粉的质量比为25∶25∶50时，在100 kHz下的有效磁导率为47.6，100 Oe下的直流偏置能力为79.5%，100 kHz/100 mT下的功率损耗为1806 mW/cm3。相比于已报道的其他含非晶软磁复合材料，本文所报道的非晶Fe-Si-B-C/Fe-Si软磁复合材料有明显的成本和综合电磁性能上的优势。细小的Fe-Si粉末可以填充粗粉之间的空隙，有利于提高材料密度与磁导率，而非晶粉末的添加则可以明显降低功率损耗。本文制备的非晶/Fe-Si软磁复合材料具备良好的综合电磁特性，可以为工业生产提供潜在的解决方案。Abstract: This work optimizes the electromagnetic properties of Fe-Si based soft magnetic composites by both modifying the composition and particle size distribution. The relationship between soft magnetic properties and microstructure is investigated. Great comprehensive electromagnetic properties can be obtained by firstly composing the Fe-Si powders with different sizes, and then partly replacing the coarse Fe-Si powder by Fe-Si-B-C amorphous powder with similar particle size. The amorphous/Fe-Si soft magnetic composites have good frequency stability within 1 MHz. When the mass ratio among Fe-Si-B-C amorphous powder, Fe-Si coarse powder, Fe-Si fine powder is 25∶25∶50, the effective permeability at 100 kHz is 47.6, the DC bias capacity at 100 Oe is 79.5%, and the power loss at 100 kHz/100mT is 1806 mW/cm3. Compared with other reported amorphous-containing soft magnetic composites, the amorphous Fe-Si-B-C/Fe-Si soft magnetic composites in this work have significant advantages in cost and combined electromagnetic properties. The Fe-Si fine powder can fill the gap between the coarse powder, which is conducive to improving the density and permeability of the soft magnetic composite, while the addition of amorphous powder can significantly reduce the power loss. The amorphous/Fe-Si soft magnetic composites prepared in this work have good comprehensive electromagnetic properties and can provide potential solutions for industrial production.
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图 1 (a) Fe-Si-B-C非晶粉、Fe-Si粗粉和Fe-Si细粉和的粒径分布；三种粉末的形貌与表面元素分布：(b) Fe-Si-B-C非晶粉(c) Fe-Si粗粉、(d) Fe-Si细粉
Figure 1. (a) Particle distribution of Fe-Si-B-C amorphous powder Fe-Si coarse powder and Fe-Si fine powder. Morphology and surface element distribution of the three powders: (b) Fe-Si-B-C amorphous powder, (c) Fe-Si coarse powder, and (d) Fe-Si fine powder
图 2 本文所用三种软磁粉末的X射线衍射图谱
Figure 2. X-ray diffraction patterns of the three soft magnetic powders in this work
图 3 本文所用三种软磁粉末的DSC曲线
Figure 3. The DSC curve of the three soft magnetic powders in this work
图 4 本文所用三种软磁粉末的磁滞曲线
Figure 4. Hysteresis loops of the three soft magnetic powders in this work
图 5 不同质量分数Fe-Si细粉添加Fe-Si级配磁粉芯的：(a)密度、(b)有效磁导率频谱、(c)直流偏置特性与(d)功率损耗
Figure 5. (a) Density, (b) dependence of effective permeability, (c) DC bias performance and (d) core loss for the Fe-Si magnetic powder cores mixed with different weight ratios of fine Fe-Si particles. The insets in b, c and d show the effective permeability at 100 kHz, percent permeability at 100 Oe, and core loss at 100 kHz, respectively
图 6 不同质量分数Fe-Si-B-C非晶粉添加的非晶/Fe-Si磁粉芯的：(a)密度、(b)有效磁导率频谱、(c)直流偏置特性与(d)功率损耗
Figure 6. (a) Density, (b) dependence of effective permeability, (c) DC bias performance and (d) core loss for the amorphous/Fe-Si magnetic powder cores mixed with different weight ratios of fine Fe-Si particles. The insets in b, c and d show the effective permeability at 100 kHz, percent permeability at 100 Oe, and core loss at 100 kHz, respectively
图 7 Fe-Si-B-C非晶粉∶Fe-Si粗粉∶Fe-Si细粉的质量比为0∶100∶0、0∶50∶50、25∶25∶50和50∶0∶50磁粉芯样品的X射线衍射图谱
Figure 7. X-ray diffraction patterns of the soft magnetic composites with mass ratios among Fe-Si-B-C amorphous powder, Fe-Si coarse powder, Fe-Si fine powder of 0∶100∶0, 0∶50∶50, 25∶25∶50 and 50∶0∶50
图 8 不同Fe-Si-B-C非晶粉∶Fe-Si粗粉∶Fe-Si细粉质量比磁粉芯的微观组织：(a) 0∶100∶0、(b) 0∶50∶50、(c) 25∶25∶50与(d) 50∶0∶50
Figure 8. Microstructure of the magnetic powder cores with different mass ratio among Fe-Si-B-C amorphous powder, Fe-Si coarse powder, and Fe-Si fine powder: (a) 0∶100∶0, (b) 0∶50∶50, (c) 25∶25∶50 and (d) 50∶0∶50
表 1 含非晶软磁复合材料的成本与电磁特性对比[14, 15, 22, 23]
Table 1. Comparison of cost and electromagnetic performance of some amorphous-containing soft magnetic composites[14, 15, 22, 23]
Material Material
cost/
(￥·kg−1)Electromagnetic performance Ref. μe at 100 kHz %μe at 100 kHz Pcv/ (mW·cm−3) at 50 kHz, 100 mT Pcm/(mW·g−1) at 50 kHz, 100 mT Pcv/ (mW·cm−3) at 100 kHz, 100 mT Pcm/(mW·g−1) at 100 kHz, 100 mT Amorphous Fe-Si-B-C/Fe-Si (Amorphous∶coarse Fe-Si∶fine Fe-Si = 25∶25∶50) 35~40 47.6 79.5% 898 138 1806 277 This work Amorphous Fe-Si-B-P-
Nb/Fe-Si57~62 60 78.0% / 159 / / [15] Amorphous Fe-Si-B-P-Nb 60~65 56 75.0% / / 1734 / [22] Amorphous Fe-Si-B-P-C 45~50 48 54.3% / / 770 / [14] Amorphous Fe-Si-B-P-
Nb-Cr/Fe-Co72~78 42.3 65.1% / / 1315 / [23] Notes: Pcv–Power loss per unit volume; Pcm–Power loss per unit mass 
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