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Novel Fabrication Method for a High-Performance Soft-Magnetic Composite Composed of Alumina-Coated Fe-Based Metal Powder

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Abstract

A high-performance soft-magnetic composite (SMC) has been successfully fabricated in a toroidal mold without the application of compaction pressure by mixing three different alumina-coated Fe-based metal powders, namely carbonyl iron (FM), Fe-Si-Cr alloy (FSC), and Fe-Si-Al alloy (sendust), with epoxy resin in a centrifugal paste mixer. Surface coating with an alumina layer was performed via a sol–gel process, and its thickness was controlled by varying the coating time. Without the alumina coating, the SMC toroidal core with a FM:FSC:sendust mixing ratio of 8:22:70 by mass exhibited optimal magnetic properties including an effective permeability (μeff) of 33.9 and total core loss (Pt) of 252 mW/cm3 at 100 kHz with an amplitude (B) of 50 mT. With the alumina coating, however, the SMC toroidal core with the same mixing ratio exhibited a significantly reduced Pt value of 213 mW/cm3 while its μeff value was slightly decreased to 32.4, primarily due to the suppression of the macroscopic eddy-current loss from 115 mW/cm3 to 85 mW/cm3. These results indicate that an optimal mixture of the three different alumina-coated Fe-based metal powders is very effective for fabricating high-performance SMC cores without external pressure for molding, being applicable for miniature electronic components.

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Acknowledgments

This research was supported by WC300 R&D (No. 10050459) by the Korean Government (SMBA).

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Authors and Affiliations

  1. Department of Materials Science and Engineering, Research Institute of Advanced Materials (RIAM), Seoul National University, Seoul, 151-744, Republic of Korea

    Sungjoon Choi, Sunwoo Lee, Chris Yeajoon Bon, KangHyuk Lee & Sang-Im Yoo

  2. Chang Sung Co Ltd, R&D Ctr, 11-9 Namdong Ind Area, Inchon, 405100, Republic of Korea

    Seong Jin Choi

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  1. Sungjoon Choi
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  2. Sunwoo Lee
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  3. Chris Yeajoon Bon
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  4. KangHyuk Lee
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Correspondence to Sang-Im Yoo.

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Choi, S., Lee, S., Bon, C.Y. et al. Novel Fabrication Method for a High-Performance Soft-Magnetic Composite Composed of Alumina-Coated Fe-Based Metal Powder. J. Electron. Mater. 50, 664–674 (2021). https://doi.org/10.1007/s11664-020-08607-8

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  • DOI: https://doi.org/10.1007/s11664-020-08607-8

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