Ultra-Low Core Loss and High-Frequency Permeability Stability in Hot-Press Sintered FeSi Soft Magnetic Composites by Fe2O3 Nanoparticles Air Gap Filling

Soft magnetic materials are crucial in motors, generators, transformers, and many electronic devices. We synthesized the FeSi soft magnetic composites (SMCs) with different doping contents of Fe₂O₃ nanopowders as fillers via the hot-press sintering technique. This work explores the incorporation of high-resistivity magnetic fillers through a novel compaction technique and investigates the influence of Fe₂O₃ nanopowder on the structure and magnetic properties of Fe₂O₃ nanopowder-filled composites. The finding reveals that Fe₂O₃ nanopowders effectively fill the air gaps between FeSi powders, increasing SMC density. Moreover, all samples exhibit excellent effective permeability frequency stability, ranging from 15 kHz to 100 kHz. Notably, the effective permeability <i>µ</i>_e improves from 22.32 to 30.45, a 36.42% increase, when the Fe₂O₃ doping concentration increases from 0 to 2 wt%. Adding Fe₂O₃ nanopowders also enhances electrical resistivity, leading to a 37.21% reduction in eddy current loss in samples for 5 wt% Fe₂O₃ addition, compared to undoped samples. Furthermore, as Fe₂O₃ content increases from 0 to 5 wt%, the power loss <i>P</i>_cv of the Fe₂O₃-doped Fe-6.5Si SMCs decreases from 25.63 kW/m³ to 16.13 kW/m³, a 37% reduction. These results suggest that Fe₂O₃-doped FeSi SMCs, with their superior soft magnetic properties, hold significant potential for use in high-power and high-frequency electronic applications.