Abstract

This study investigated the effect of the water and gas atomized Fe–Si powders on the densification behavior and consequential magnetic properties of the sintered soft magnetic alloys by metal injection molding. The water and gas atomized Fe–Si powders were used to fabricate the injection molded parts with the same solids loading of 58 vol% to analyze the inherent characteristics of each powder admixture. Dilatometry analysis was performed to understand the densification behavior of the water and gas atomized powders, and the master sintering curve model was developed to quantify the differences. The results showed that a significant amount of oxides in the water atomized powder reduced not only the densification but also the overall magnetic properties. The gas atomized sample exhibited the higher sintered density than the water atomized sample, and consequentially higher magnetic induction was obtained. The lower core loss, lower coercivity, and the higher permeability were also obtained from the gas atomized sample with the relatively low oxide level and large grain size. In addition, Fe-10.2 wt% P (Fe-17 at% P) powder was added to activate the liquid phase sintering, as a method to overcome the weakness of poor densification of the Fe–Si powders. Although both the water and gas atomized samples achieved near-full density with Fe-10.2 wt% P, the gas atomized sample yielded superior magnetic properties as compared with the water atomized sample.

Graphical Abstract

中文翻译：

---

气，水雾化成型的Fe-Si合金的致密化和磁性能以及Fe-10.2 wt％P添加的影响

摘要

这项研究研究了水和气体雾化的Fe-Si粉末对金属注射成型烧结软磁合金的致密化行为和随之产生的磁性能的影响。水和气体雾化的Fe-Si粉末用于制造固含量为58 vol％的注射成型零件，以分析每种粉末混合物的固有特性。进行了膨胀分析，以了解水和气体雾化粉末的致密化行为，并开发了主烧结曲线模型以量化差异。结果表明，水雾化粉末中大量的氧化物不仅降低了致密化，而且降低了总体磁性能。气体雾化样品比水雾化样品具有更高的烧结密度，从而获得更高的磁感应强度。还从具有相对较低的氧化物水平和较大的晶粒尺寸的气体雾化样品获得了较低的铁损，较低的矫顽力和较高的磁导率。此外，添加Fe-10.2 wt％P（Fe-17 at％P）粉末以激活液相烧结，以此作为克服Fe-Si粉末致密性差的方法。尽管水和气体雾化的样品都达到了Fe-10.2 wt％P的接近全密度，但是与水雾化的样品相比，气体雾化的样品产生了优越的磁性。添加Fe-10.2 wt％P（Fe-17 at％P）粉末以激活液相烧结，以此作为克服Fe-Si粉末致密性差的方法。尽管水和气体雾化的样品都达到了Fe-10.2 wt％P的接近全密度，但是与水雾化的样品相比，气体雾化的样品产生了优越的磁性。添加Fe-10.2 wt％P（Fe-17 at％P）粉末以激活液相烧结，以此作为克服Fe-Si粉末致密性差的方法。尽管水和气体雾化的样品都达到了Fe-10.2 wt％P的接近全密度，但是与水雾化的样品相比，气体雾化的样品产生了优越的磁性。

图形概要