Enhancing the High-Frequency Performance of FeSiAl/2.25 wt.% WS2 Composites Through the Application of a Transverse Magnetic Field

Herein, we address the challenge of high core losses in soft magnetic composites (SMCs) at high frequencies by developing a FeSiAl/WS2 composite system processed under a transverse magnetic field (TMF). In this study, 200- and 600-mesh FeSiAl powders were used as base materials and combined with 2.25 wt.% two-dimensional tungsten disulfide (WS2; an insulating agent) to prepare FeSiAl/2.25 wt.%WS2 soft magnetic composites via ultrasonic mixing. The evolution of soft magnetic properties under a transverse magnetic field (TMF) was systematically investigated. The novelty of this work lies in the synergistic combination of fine FeSiAl particles and WS2 nanosheets as an interparticle insulator and the application of a TMF to simultaneously suppress eddy current and hysteresis losses—a challenge that is difficult to address using conventional approaches. Morphological analysis confirmed a uniform and continuous organic coating of WS2 nanosheets on FeSiAl particle surfaces. Permeability measurements revealed a slight decrease in effective permeability after the TMF treatment; however, the high-frequency performance was markedly enhanced. Magnetic loss analysis revealed a substantial reduction in the hysteresis loss and an increase in the quality factor under the TMF. Notably, the FeSiAl (600 mesh)/2.25 wt.% WS2 composite achieved a total magnetic loss of 234 kW/m3 under a TMF of 140 kA/m, magnetic induction of 20 mT, and frequency of 1 MHz, representing a 69% reduction compared with conventional SMCs. These results not only validate the effectiveness of the proposed synergistic approach but also highlight the potential of FeSiAl (600 mesh)/2.25 wt.% WS2 for use in high-power, high-frequency magnetic devices, with improved energy efficiency and thermal performance.