Research progresses on amorphous soft magnetic composites

<p indent="0mm">The rapid progression of third-generation semiconductors, new energy technologies, and next-generation communication systems has led to an increased demand for power electronic devices, particularly in high-frequency applications. The significance of high-frequency eddy current losses cannot be underestimated, and energy efficiency has emerged as a crucial impetus for the advancement of novel materials. Amorphous soft magnetic composites represent a new category of soft magnetic materials, which are derived from traditional powder metallurgy techniques, involving the insulation coating of amorphous powders and subsequent compression molding. Compared with conventional soft magnetic materials, amorphous soft magnetic composites offer several advantages, including three-dimensional magnetic isotropy, significantly reduced eddy current losses, lower core losses at medium and high frequencies, enhanced resistance to direct current bias, and superior comprehensive soft magnetic properties. Additionally, these materials facilitate flexible machine design and assembly, enabling the fabrication of complex and miniature devices. This study provides a comprehensive review of recent researches on amorphous soft magnetic composites, focusing on various aspects such as the preparation of amorphous powders, insulation coating and molding techniques, heat treatment processes, microstructure and soft magnetic property regulation, as well as the development of magnetic powder cores manufactured by nanoscale amorphous powder. Furthermore, we anticipate the future research trends in this field, alongside the key challenges, prospects and applications associated with amorphous soft magnetic composites.