Abstract Efficient and cost-effective soft magnetic materials (SMMs) are essential for accelerating the adoption of electric vehicles and the sustainable growth of renewable electricity. While amorphous and nanocrystalline SMMs offer remarkably low magnetic losses, their poor mechanical properties, limited availability in size and shape (particularly ribbon widths), and high cost prevent them from widespread industrial application. Here, we show that ductile Fe-6.5%Si 2-D flakes could be used as building blocks for making high performance bulk SMMs. This approach bypasses the brittleness problem and creates a new morphology and a new fabrication method for the SMMs with improved energy efficiency and lower processing cost. Ductile Fe-6.5%Si flakes are mass-produced by melt spinning and are then consolidated to bulk SMMs with a brick-wall type of structure. The novel process introduces anisotropic electrical and magnetic properties and enables near net shape processing. Resulting Fe-6.5%Si thin sheets display low iron loss (W10/400 = 6.1 W/kg) and high permeability (µr = 28,000), which are comparable to the current state of the art high silicon steel. CaF2 coating reduces the iron losses for thick Fe-6.5%Si parts. Polymer coated Fe-6.5%Si flake cores show potential for high power inductors with greater permeability and lower losses than traditional powder cores.

中文翻译：

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各向异性 Fe-6.5%Si 软磁材料的近净成形制备

摘要 高效且具有成本效益的软磁材料 (SMM) 对于加速电动汽车的采用和可再生电力的可持续增长至关重要。虽然非晶和纳米晶 SMM 的磁损耗非常低，但它们的机械性能差、尺寸和形状（尤其是带宽度）的可用性有限以及成本高，阻碍了它们的广泛工业应用。在这里，我们展示了延展性 Fe-6.5% Si 2-D 薄片可用作制造高性能块状 SMM 的构件。这种方法绕过了脆性问题，为 SMM 创造了一种新的形态和新的制造方法，具有更高的能量效率和更低的加工成本。延展性 Fe-6。5% Si 薄片通过熔体纺丝大量生产，然后被固结成具有砖墙类型结构的块状 SMM。新工艺引入了各向异性的电学和磁学特性，并实现了近净形加工。由此产生的 Fe-6.5%Si 薄片显示出低铁损 (W10/400 = 6.1 W/kg) 和高磁导率 (µr = 28,000)，可与当前最先进的高硅钢相媲美。CaF2 涂层降低了厚 Fe-6.5%Si 零件的铁损。聚合物涂层的 Fe-6.5%Si 片状磁芯显示出比传统粉末磁芯具有更高磁导率和更低损耗的高功率电感器的潜力。1 W/kg) 和高磁导率 (µr = 28,000)，可与目前最先进的高硅钢相媲美。CaF2 涂层降低了厚 Fe-6.5%Si 零件的铁损。聚合物涂层的 Fe-6.5%Si 片状磁芯显示出比传统粉末磁芯具有更高磁导率和更低损耗的高功率电感器的潜力。1 W/kg) 和高磁导率 (µr = 28,000)，可与目前最先进的高硅钢相媲美。CaF2 涂层降低了厚 Fe-6.5%Si 零件的铁损。聚合物涂层的 Fe-6.5%Si 片状磁芯显示出比传统粉末磁芯具有更高磁导率和更低损耗的高功率电感器的潜力。