Low-loss and high-induction Fe-based soft magnetic composites coated with magnetic insulating layers

We have provided a new and simple coating strategy to fabricate high-performance metal-based magnetic composites exhibiting both high magnetic inductions and decreased core loss. High-purity submicron FeCo particles have been dispersed into silicone resin to form a magnetic insulating film, which is then coated uniformly on the particle surface of high-purity Fe powders with a particle size of 170 μm to form new-type Fe-based soft magnetic composites (SMCs). These insulated magnetic layers containing submicron FeCo particles in these Fe-based SMCs can maintain very high saturated magnetization (209 A·m²·kg⁻¹) for the composites, and also result in their low core loss. For traditional metal-based SMCs, the low core loss is often obtained accompanying with seriously decreased magnetic inductions. In present work, both high magnetic inductions and decreased core loss in company with high compacted density are achieved in these Fe-based SMCs coated with magnetic insulating coating layers. Specifically, the extremely low eddy current loss occurring in these new Fe-based SMCs enables their latent applications in low-loss and high-power magnetic devices.