Influence of Atomization Parameters on Sphericity and Soft Magnetic Properties of FeSiBNbCu Nanocrystalline Powders

Hybrid atomization represents a novel method for powder production with high cooling and crushing capacities, but previous studies have primarily focused on tin and aluminum alloy systems. In present study, FeSiBNbCu nanocrystalline powders were prepared using a hybrid atomization system and the effects of atomization parameters on the sphericity of the powders and soft magnetic properties of the nanocrystalline magnetic powder cores (NMPCs) were investigated. Orthogonal experiments reveal that atomization pressure is the most critical factor affecting powder size, while melting temperature primarily influences sphericity. By optimizing the atomization parameters, the nanocrystalline powders with a high sphericity of up to 91.2% can be achieved, and the core loss at 1 MHz@20 mT of the corresponding NMPCs is reduced by 59.2% to 464 mW/cm3. This study provides valuable guidance for the fabrication of Fe-based nanocrystalline powders with excellent soft magnetic properties via hybrid atomization.