High-performance Fe–Si soft magnetic composites with controllable silicate/nano-Fe composite coating

The design of magnetic insulation coating structure has always been a challenge for high-performance soft magnetic composites (SMCs). In this work, we prepared Fe–Si SMCs with silicate/nano-Fe composite coating successfully by in-situ oxidation method combined with spark plasma sintering (SPS). The formation mechanism of the composite coating and its effect on the electro-magnetic properties of Fe–Si SMCs were investigated. The results showed that a uniform Fe2O3 coating can be obtained by reactions between Fe and H2O/O2 during in-situ oxidation process, and became thicker with the increased oxidation time. After sintering, the oxide coating was transformed into a composite coating composed of Fe2SiO4 with excellent insulation and nano-Fe with high ferromagnetism, which resulted from the interfacial reaction between Fe2O3 coating and Fe–Si core. The increased oxidation time led to the gradually thicker composite coating, and resulted in a linear decrease in saturation magnetization, indicating good controllability of the coating. However, excessive oxidation time led to the increased eddy current loss as well as the core loss due to the weakened resistivity. Thus, the Fe–Si SMCs exhibited high saturation magnetic induction (1.66T) and very low core loss (643.9 kW/m3 at 0.1 T/50 kHz) especially when the oxidation time was 1 h.