- Email: [email protected]
Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy
Journal of Alloys and Compounds xxx (xxxx) xxx
Contents lists available at ScienceDirect
Journal of Alloys and Compounds journal homepage: http://www.elsevier.com/locate/jalcom
Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy Wangchang Li a, Yang Zheng a, Yue Kang b, Ansar Masood c, Yao Ying a, Jing Yu a, Jingwu Zheng a, Liang Qiao a, Juan Li a, Shenglei Che a, * a b c
College of Materials Science and Engineering, Zhejiang University of Technology, Hangzhou, 310014, China School of Materials Science and Engineering, Tsinghua University, Beijing, 100084, China Microsystems Centre, Tyndall National Institute, University College Cork, Cork, Ireland
a r t i c l e i n f o
a b s t r a c t
Article history: Received 11 September 2019 Received in revised form 12 November 2019 Accepted 13 November 2019 Available online xxx
Herein, flake-like FeSiAl particles are prepared by rapid quenching and subsequent ball milling processes. Then, soft magnetic composites are fabricated by orderly aligned flake-like FeSiAl particles, resulting in the formation of nacre-like structure. The influence of processing parameters on columnar microstructure of the thin strips has been studied in detail. Furthermore, the magnetic permeability and loss of the soft magnetic composites, with different compositions, are explored. The results reveal that the soft magnetic composite, with flake-like Fe85Si9.6Al5.4, renders the magnetic permeability of 200 at 1 MHz, which is much higher than the spherical FeSiAl particles. Moreover, the negative temperature-dependent loss and a valley temperature of 65 C are observed at the Sendust composition of Fe85Si8.8Al6.2, which maintained the magnetic permeability of 172 at 1 MHz and a loss of 380 kW/m3 at 50 kHz (stimulated at 100 mT). It is worth emphasizing that the nacre-like SMC exhibits outstanding properties and renders promise for next-generation magnetic devices. © 2019 Elsevier B.V. All rights reserved.
Keywords: Rapidly quenched Nacre-like structure Flake-like FeSiAl alloy Complex permeability Temperature-dependent loss characteristics
1. Introduction Soft magnetic composites (SMC) are constructed by combining soft-magnetic metallic particles with insulating materials through the powder metallurgy route [1], followed by annealing at an optimal temperature [2]. In general, compared to the soft magnetic ferrite, soft magnetic metallic alloys, such as FeNi, FeSiAl, and FeCoNi [3], exhibit high saturation magnetization at the expense of resistivity, resulting in high eddy current loss at high frequency. Therefore, SMCs are employed to enhance the resistivity through the insulating boundary to reduce the eddy current loss and maintain high saturation magnetization, which is sorely required for next-generation semiconductor switching power supplies [1]. Moreover, the coating can be divided into two types: inorganic and organic insulants. However, the organic coatings, i.e., phenolic resin [4], are destroyed at high temperatures and, therefore, cannot be annealed. On the other hand, the inorganic coatings, such as FePO4 [5,6], MgO [7], SiO2 [8], Al2O3 [9], Fe3O4 [10], NiCuZn ferrite [11] and
* Corresponding author. E-mail address: [email protected] (S. Che).
MnZn ferrite [12], can be annealed at high temperatures. It is worth emphasizing that silica is a typical inorganic coating material, which is widely utilized in soft magnetic composites due to its high-temperature resistance [13,14]. In recent years, amorphous and non-crystalline particles have been developed for advanced devices [15,16]. SMCs are widely employed in electronic components due to their tunable magnetic permeability, high saturation magnetization and low magnetic loss [17,18]. However, the magnetic permeability of SMC, prepared by using spherical powders, is usually limited to 120 [19] and the applied frequency is usually lower than 100 kHz. One should note that the low magnetic permeability limits the practical utilization of SMCs in miniaturized devices, which implies that the development of SMCs, with superior magnetic permeability, is of utmost importance [20,21]. In fact, magnetic permeability and loss are related to the shape, dimension, and composition of particles [22,23]. According to Aharoni’s equation [24] and Snoek’s law [25], the relationship between permeability and the particle shape determines the demagnetization factor in different directions. Previously, our group has fabricated a nacre-like SMC [26] and demonstrated excellent permeability and low loss in the high-frequency regime.
https://doi.org/10.1016/j.jallcom.2019.153028 0925-8388/© 2019 Elsevier B.V. All rights reserved.
Please cite this article as: W. Li et al., Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy, Journal of Alloys and Compounds, https://doi.org/10.1016/j.jallcom.2019.153028
2
W. Li et al. / Journal of Alloys and Compounds xxx (xxxx) xxx
However, flake-like FeSiAl particles are difficult to obtain due to high hardness and brittleness of FeSiAl. Therefore, FeSiAl alloys are produced by either mechanical alloying or ball milling [27]. Rapid quenching is an efficient method of directly producing flake-like FeSiAl particles [28]. It has been reported that flake-like FeSiAl particles render superior performance due to their unique morphology. For instance, Haichen et al. [29] have studied the microstructural evolution of FeSiAl alloy during rapid quenching and demonstrated a fine-grained structure with superior saturation magnetization. Wei et al. [30] have synthesized flake-like FeSiAl alloy by rapid quenching method, which exhibited better electromagnetic properties. Hence, rapid quenching method can be utilized to fabricate flake-like alloy powder. On the other hand, FeSiAl alloy exhibits thermal failure behavior and the loss rapidly increases with increasing temperature, limiting the practical utilization of FeSiAl alloy in electronic devices due to the inevitable generation of heat and corresponding temperature increase during operation. Yanagimoto et al. [31] have observed the temperature-dependent magnetic behavior of FeSiAl SMC can be altered by tuning the content of Si and Al. Previously, we have reported the fabrication of SMCs by using metallic powders, however, the spherical morphology of the asprepared SMC rendered low permeability due to the effective anisotropy field, which is related to the shape of particles. Herein, we aimed to fabricate a soft magnetic lamellar composite by orderly aligning the flake-like FeSiAl particles, resulting in superior soft magnetic properties. The magnetic permeability of flake-like FeSiAl powder is significantly improved due to nacre-like structure. Moreover, different compositions of flake-like FeSiAl powder have been fabricated by rapid quenching, and the influence of process parameters on morphological evolution has been systematically investigated. Furthermore, we have explored the magnetic properties of as-prepared FeSiAl powder and the nacrelike magnetic ring. The nacre-like SMC exhibits promise for the future development of miniaturized magnetic devices. 2. Experimental section 2.1. Strip fabrication. (Melting and quenching) First, high purity metals, i.e., Fe (99%), Si (99%) and Al (99%), were melted to form an alloy ingot under argon atmosphere. Four different compositions of FeSiAl alloy, i.e., Fe85Si8Al7, Fe85Si8.8Al7.2, Fe85Si9.6Al5.4, and Fe85Si11Al4, were prepared by adjusting the ratio of different metals. Then, FeSiAl ribbon (~20 mm) was obtained by the rapid quenching method. Briefly, FeSiAl alloy ingot was placed in a quartz tube and the chamber is evacuated to <103 Pa. Then, the argon gas was filled into the chamber to reach a pressure of 50 Pa. The quartz tube was placed in the middle of a heating coil. Then, the current was slowly adjusted to 25 A for heating and the molten metal from the quartz tube was sprayed on a high-speed rotating copper (Cu) wheel. The molten metal was rapidly solidified and detached from the Cu wheel to obtain a thin strip. The asobtained thin strips of FeSiAl alloy were annealed at 700 C for 2 h. 2.2. Powder synthesis The as-prepared FeSiAl alloy strips were ball milled to further reduce the thickness of Sendust particles to achieve a low loss in the high-frequency regime. Briefly, 1000 g of hard steel balls and thin strip were added into a grinding jar with an appropriate amount of ethanol and the BPR was 50:1. Moreover, 35 wt % glycerol was added to control the viscosity of the solution. The ball milling was carried out for 4 h, and the as-received FeSiAl particles were dried in a vacuum oven at 60 C, followed annealing at 700 C
in a nitrogen atmosphere. 2.3. Fabrication of magnetic ring Furthermore, the flake-like FeSiAl powder was coated by using € ber coating method [32]. In a typical process, a certain amount Sto of FeSiAl powder was mixed with deionized water and absolute ethanol solution, followed by ultrasonic dispersion for 15 min. Then, 0.125 mL of NH3$H2O solution was slowly added and stirred for 30 min, followed by the addition of 0.25 mL of TEOS and stirring at 30 C for 4 h. Finally, the coated powder was rinsed with absolute ethanol and vacuum dried at 60 C. Moreover, a lubricant (0.3% zinc stearate) was mixed into the powder. Then, FeSiAl powder was layer-by-layer compacted under a pressure of 1200 MPa to prepare a magnetic ring with an outer diameter of 12.7 mm, an inner diameter of 7.6 mm and a thickness of 2 mm. The as-prepared magnetic ring was annealed at 700 C for 4 h. 2.4. Characterization The microscopic structure was observed by using a scanning electron microscope (SEM, Hitachi SU1510). X-ray diffraction (XRD, PANalytical X’Pert PRO X) was employed to investigate the crystal structure. The permeability of the magnetic ring was measured at room temperature in the frequency range of 1 MHz to 1 GHz by using an RF impedance analyzer (Agilent E4991). Hysteresis loop and loss were measured by using a vibrating sample magnetometer (VSM, Lake Shore 7410) and a BeH analyzer (SY-8218, IWATSU). The electrical resistivity was measured by using four-point probe (RTS8). 3. Results and discussion 3.1. Structural and morphological characterization It is worth noting that the rotational speed of the Cu wheel during the rapid quenching process significantly influenced the microstructure of magnetic ribbon. At low rotational speed, the heat is effectively transferred from the molten alloy to the Cu wheel, providing sufficient time for nucleation and growth of FeSiAl alloy on Cu wheel. However, at a high rotational speed, the finegrained structure is observed due to the faster cooling process. As shown in Fig. 1b, the thickness of the ribbon at a rotational velocity of 48 m s1 was ~20 mm. On the other hand, the thickness of the ribbon at a rotational velocity of 32 m s1 was ~45 mm. The XRD patterns of FeSiAl alloys, prepared at different rotational velocities, are presented in Fig. 2. At a rotational velocity of 8 m s1, the diffraction peaks of (200) and (400) planes of FeSiAl alloy are stronger than the samples prepared at higher rotational velocities, such as 48 m s1, whereas the diffraction peak of (422) planes is weaker. XRD results reveal the oriented growth of crystal grains. At lower rotational speed, the grain growth occurred along the (400) planes of FeSiAl alloy, whereas (220) and (422) planes became dominant with increasing rotational speed. One should note that the grain growth is initiated with the solidification of molten metal and the high rotational speed suppresses the grain growth in certain planes due to the insufficient nucleation time. 3.2. Characterization of the magnetic powder The flake-like FeSiAl powder, with a transverse diameter of 50 mm, has been successfully fabricated after ball milling, as shown in Fig. 3. Moreover, FeSiAl alloy exhibited a disordered body center cubic (BCC) and ordered DO3 structure, where (220), (400), (422) peaks belong to BCC phase and (111), (200) and (311) peaks
Please cite this article as: W. Li et al., Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy, Journal of Alloys and Compounds, https://doi.org/10.1016/j.jallcom.2019.153028
W. Li et al. / Journal of Alloys and Compounds xxx (xxxx) xxx
3
Fig. 1. The cross-sectional SEM images of the magnetic ribbon at a rotational speed of (a) 32 m s1 and (b) 48 m s1.
the diffraction peak, corresponding to (111) planes, became obvious after ball milling, which can be ascribed to the formation of DO3 phase due to the occupation of Fe sites by Si and Al atoms in the aFe lattice. The hysteresis loops of different compositions of FeSiAl powder are obtained by using a vibrating sample magnetometer (VSM), and the results are shown in Fig. 4. At 25 C, the hysteresis loop did not exhibit any significant change with respect to composition and different compositions of FeSiAl powder rendered soft magnetic properties. Moreover, the Ms values of Fe85Si8Al7, Fe85Si8.8Al7.2, Fe85Si9.6Al5.4, and Fe85Si11Al4 alloys were found to be 119.4 emu$g1, 120.96 emu$g1, 113.86 emu$g1 and 117.97 emu$g1, respectively. On the other hand, the coercive force has been significantly altered with compositional variations. In general, the coercivity is decreased with increasing Si content. Hence, Fe85Si8Al7 and Fe85Si11Al4 alloy exhibited coercivity values of 41.75 Oe and 21.97 Oe, respectively. Fig. 2. XRD pattern of FeSiAl alloy, prepared at different rotational velocities.
correspond to the ordered DO3 phase. After rapid quenching, BCC structure has been observed as the main phase, which is indicated by the presence of (220) and (400) peaks. Moreover, both Al and Si occupy the Fe sites during rapid quenching, resulting in a thin band with an ordered phase. Moreover, the ordered phase disappeared after ball milling, resulting in the appearance of (110), (200) and (211) peaks. One should note that the ball milling process induced dislocations and defects in FeSiAl particles, increasing the energy of alloy constituents. Hence, Si and Al atoms are separated from the a-Fe lattice, rendering a completely disordered structure. However, after annealing at 700 C, ordered DO3 phase re-emerged, as evidenced by strong (111) and (200) diffraction peaks. It is worth noting that
3.3. Magnetic properties and loss of SMC Fig. 5 presents the morphology of flake-like FeSiAl-coated SiO2 and the microstructure of the magnetic core. It can be readily observed that a thin layer of SiO2 is formed on the surface of flakelike FeSiAl powder and the sheet-like FeSiAl formed an ordered structure of layered stacks. Moreover, the SiO2 coating layer is observed between the flakes, which is similar to the brick-mud structure of the shell. Table 1 shows the resistivity of different samples, and the resistivity is closely related to loss. The excellent properties of FeSiAl are only in a small composition range, and the resistivity of Fe85Si8Al7 is 32.5 U m, which is far below that of the Fe85Si8.8Al6.2 and Fe85Si9.6Al5.4. This may be the reason for the high loss of the Fe85Si8Al7 sample. The loss of FeSiAl is extremely sensitive to composition. When the composition in FeSiAl deviates too much
Fig. 3. (a) SEM image of FeSiAl particles after ball milling and (b) XRD patterns of FeSiAl alloys during different preparation stages.
Please cite this article as: W. Li et al., Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy, Journal of Alloys and Compounds, https://doi.org/10.1016/j.jallcom.2019.153028
4
W. Li et al. / Journal of Alloys and Compounds xxx (xxxx) xxx
Fig. 4. (a) Hysteresis loops and (b) magnetic properties of different compositions of FeSiAl powder, where blue and red columns represent the saturation magnetization and coercivity. (For interpretation of the references to colour in this figure legend, the reader is referred to the Web version of this article.)
Fig. 5. (a) The morphology and (b) cross-sectional SEM image of flake-like sendust@SiO2 particles, where (b) shows the nacre-like structure.
Table 1 Resistivity of different samples. Component
Fe85Si8Al7
Fe85Si8.8Al6.2
Fe85Si9.6Al5.4
Fe85Si11Al4
Resistivity (Um)
32.5
83.1
87.9
48.42
from Fe85Si9.6Al5.4, the performance changes greatly, as Fe85Si8Al7 and Fe85Si11Al4, in which the resistivity reduced from 87.9 U m to 32.5 U m and 48.42 U m, respectively. Fig. 6 shows the magnetic permeability of different compositions of FeSiAl at high frequency. The real magnetic permeability of the sheet-like FeSiAl powder core reached a value of 200 in the frequency range of 1e1000 MHz, which is far higher than the traditional SMCs. According to the theory [33], two resonance peaks should be observed in the imaginary part of the magnetic permeability curve, which is mainly related to the composition of the magnetic spectrum. One should note that the magnetic
spectrum is mainly composed of the domain wall resonance and spin resonance, where the spin resonance is related to the ferromagnetic resonance and the magneto crystalline anisotropy field. But now there is only one resonance being observed. It should be that the spin resonance component affects much more than the domain wall component. It has been observed that a change in alloy composition significantly deteriorated the magnetic properties of the composites. For instance, when the alloy composition significantly deviates from Fe85Si9.6Al5.4, the magnetic permeability is rapidly decreased and exhibited a value of 100, which is almost half of the magnetic permeability of Fe85Si9.6Al5.4. However, the slight deviation from Fe85Si9.6Al5.4 resulted in small change in magnetic permeability. For instance, Fe85Si9.6Al5.4 exhibited a magnetic permeability of 172. Furthermore, the loss characteristic of Fe85Si8.8Al6.2 is similar to ferrite, and a valley temperature is observed at 65 C. In the case of Fe85Si8Al7, the loss exhibited a negative temperature-dependent
Fig. 6. (a) The frequency-dependent complex permeability and (b) temperature-dependent loss of different compositions of FeSiAl alloy.
Please cite this article as: W. Li et al., Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy, Journal of Alloys and Compounds, https://doi.org/10.1016/j.jallcom.2019.153028
W. Li et al. / Journal of Alloys and Compounds xxx (xxxx) xxx
behavior, which can be ascribed to the relationship between the magnetic crystal coefficients and Si content. Moreover, an extremely high value of which loss has been observed at 25 C, which decreased with increasing temperature. In the case of Fe85Si9.6Al5.4, the loss linearly increased with increasing temperature due to the decrease in resistivity, resulting in an increased eddy current loss. One should note that the magnetic crystal coefficient K and magnetostriction coefficient are related to the Si content, indicating the difficulty of magnetic domain movement. Moreover, magnetic crystal coefficients and magnetostriction coefficient are closely related to the temperature dependence of the loss. At the Si content of 9.6 wt % and K > 0, the loss has exhibited a positive relationship with temperature, whereas, at the Si content of 8 wt % and K < 0, the loss has exhibited a negative temperature dependence. At the Si content of 8.8 wt % and K ¼ 0, a valley temperature occurs, where the magnetic domain is most likely to move. On the other hand, the magnetostriction coefficient has exhibited an opposite trend. Apart from the magnetic crystal coefficient magnetostriction coefficient, it can explain from the study of Samuel Dob ak et al. [34,35], domain walls motion and magnetization rotation were closely related to loss. When the temperature rised, mechanical stresses were relieved and the anisotropy reduction, resulting in reduced sample loss.
4. Conclusions In summary, FeSiAl thin strips have been successfully fabricated by a rapid quenching method. The thickness of the magnetic ribbon decreased with increasing the rotation speed of Cu wheel. Once the rotation speed of Cu wheel is increased from 32 m s1 to 48 m s1, the thickness of the magnetic ribbon decreased from 45 mm to 20 mm. Moreover, preferential grain growth has been observed after rapid quenching, where the grain growth is initiated along (422) planes, followed by (200) and (400) planes. In addition, ordered DO3 phase reappeared after annealing at 700 C. Furthermore, a high magnetic permeability (u’ ¼ 200 at 1 MHz) is obtained by uniformly mixing the rapidly quenched Fe85Si9.6Al5.4 with SiO2. Moreover, the loss behavior has been influenced by compositional changes. In general, the loss is linearly increased with increasing temperature. At 0 C, Fe85Si9.6Al5.4-containing SMC rendered a loss of 313.5 kW/m3, which increased to 413.77 kW/m3 at 65 C. In the case of Fe85Si8.8Al6.2, the loss curve exhibited a similar trend with ferrite, i.e., the loss decreased with increasing temperature till a valley temperature (~65 C), resulting in a loss value of 380 kW/m3 and magnetic permeability of 172 at 1 MHz Moreover, the loss has exhibited a negative temperature dependence in the case of Fe85Si8Al7, resulting in a loss value of 571.84 kW/m3 at 145 C.
Author contributions Wangchang Li: Conceptualization, Methodology, Writing Original Draft, Writing - Review & Editing. Yang Zheng: Methodology, Data Curation, Investigation. Yue Kang: Writing - Review & Editing. Ansar Masoodc: Writing - Review & Editing. Yao Ying: Writing - Review & Editing. Jing Yu: Writing - Review & Editing. Jingwu Zheng: Writing - Review & Editing. Liang Qiao: Writing - Review & Editing. Juan Li: Writing - Review & Editing. Shenglei Che: Resources, Supervision, Project administration.
5
Declaration of competing interest Neither the entire paper nor any part of its content has been published or accepted elsewhere. It is not being submitted to any other journal. All authors (Wangchang Li, Yang Zheng, Yue Kang, Ansar Masood, Yao Ying, Jing Yu, Jingwu Zheng, Liang Qiao, Juan Li, Shenglei Che) approve to submit the manuscript to your journal. The authors declare that they do not have any conflict of interest. Acknowledgements This work was supported by National Nature Science Foundation of China through Grant No.51602283 and No. 11404397. References [1] H. Shokrollahi, K. Janghorban, Soft magnetic composite materials (SMCs), J. Mater. Process. Technol. 189 (2007) 1e12. [2] W. Li, Z. Wang, In-situ formation of Fe3O4 and ZrO2 coated Fe-based soft Magnetic Composites by hydrothermal method, Ceram. Int. 45 (2019) 3864e3870. [3] M. Persson, Development in soft magnetic components, Met. Powder Rep. 55 (2000) 10e11. [4] M.M. Dias, H.J. Mozetic, J.S. Barboza, et al., Influence of resin type and content on electrical and magnetic properties of soft magnetic composites (SMCs), Powder Technol. 237 (2013) 213e220. [5] A.H. Taghvaei, H. Shokrollahi, K. Janghorban, Prope rties of iron-based soft magnetic composite with iron phosphateesilane insulation coating, J. Alloy. Comp. 481 (2009) 681e686. [6] D.Z. Xie, K.H. Lin, S.T. Lin, Effects of processed parameters on the magnetic performance of a powder magnetic core, J. Magn. Magn. Mater. 353 (2014) 34e40. [7] A.H. Taghvaei, A. Ebrahimi, M. Ghaffari, K. Janghorban, Magnetic properties of iron -based soft magnetic composites with Mgo coating obtained by solegel method, J. Magn. Magn. Mater. 322 (2010) 808e813. [8] S. Wu, A. Sun, Z. Lu, C. Cheng, X. Gao, Magnetic properties of iron -based soft magnetic composites with SiO2 coating obtained by reverse microemulsion method, J. Magn. Magn. Mater. 381 (2015) 451e456. [9] M. Yaghtin, A.H. Taghvaei, B. Hashemi, K. Janghorban, Effect of heat treatment on magnetic properties of iron-based soft magnetic composites with Al2O3 insulation coating produced by solegel method, J. Alloy. Comp. 58 (2013) 293e297. [10] J. Li, J. Yu, W. Li, S. Che, J. Zheng, L. Qiao, Y. Ying, The preparation and magnetic performance of the iron-based soft magnetic composites with the Fe@Fe3O4 powder of in situ surface oxidation, J. Magn. Magn. Mater. 454 (2018) 103e109. [11] W. Li, W. Wang, J. Lv, Y. Ying, J. Yu, J. Zheng, L. Qiao, S. Che, Structure and magnetic properties of iron-based soft magnetic composite with Ni-Cu-Zn ferriteesilicone insulation coating, J. Magn. Magn. Mater. 456 (2018). [12] S. Wu, A. Sun, W. Xu, Q. Zhang, F. Zhai, P. Logan, A.A. Volinsky, Iron -based soft magnetic composites with MneZn ferrite nanoparticles coating obtained by solegel method, J. Magn. Magn. Mater. 324 (2012) 3899. [13] B. Yang, Z. Wu, Z. Zou, R. Yu, High -performance Fe/SiO2 soft magnetic composites for low and high-power applications, J. Phys. D Appl. Phys. 43 (2010). [14] Y.W. Zhao, X. Zhang, J. Xiao, Submicrometer lami nated Fe/SiO2 soft magnetic compositesdan effective route to materials for high- frequency applications, Adv. Mater. 17 (2010) 915e918. [15] D.H. Ping, Y.Q. Wu, K. Hono, M.A. Willard, M.E. Mchenry, D.E. Laughlin, Microstructural characterization of (Fe0.5Co0.5)88Zr7B4Cu1 nanocrystalline alloys, Scr. Mater. 45 (2001) 781e786. [16] M.A. Willard, D.E. Laughlin, M.E. Mchenry, D. Thoma, K. Sickafus, J.O. Cross, V.G. Harris, Structure and magnetic properties of (Fe0.5Co0.5)88Zr7B4Cu1 nanocrystalline alloys, J. Appl. Phys. 84 (1998) 6773e6777. [17] A. Ozols, M. Pagnola, D.I. García, H. Sirkin, Electroless coating of Permalloy powder and DC-resistivity of alloy composites, Surf. Coat. Technol. 200 (2006) 6821e6825. D a , S. Dob kov berova , R. Bures, [18] J. Füzer, M. Stre ckova ak, L. a, P. Koll ar, M. Fa Y. Osadchuk, P. Kurek, M. Vojtko, Innovative ferrite nanofibres reinforced soft magnetic composite with enhanced electrical resistivity, J. Alloy. Comp. 753 (2018) 219e227. [19] J. Li, X. Peng, Y. Yang, H. Ge, Preparation and characterization of MnZn/FeSiAl soft magnetic composites, J. Magn. Magn. Mater. 426 (2017) 132e136. [20] M.L. Tuballa, M.L. Abundo, A review of the development of Smart Grid technologies, Renew. Sustain. Energy Rev. 59 (2016) 710e725. [21] B. Zhao, Q. Song, W. Liu, et al., Overview of dual-active-bridge isolated bidirectional DCeDC converter for high-frequency-link power-conversion system, IEEE Trans. Power Electron. 29 (2014) 4091e4106. [22] S. Yoshida, M. Sato, E. Sugawara, Y. Shimada, Permeability and electromagnetic-interference characteristics of Fe-Si-Al alloy flakes-polymer
Please cite this article as: W. Li et al., Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy, Journal of Alloys and Compounds, https://doi.org/10.1016/j.jallcom.2019.153028
6
W. Li et al. / Journal of Alloys and Compounds xxx (xxxx) xxx
composite, J. Appl. Phys. 85 (1999) 4636e4638. [23] M. Stre ckov a, L. Medvecký, J. Füzer, P. Koll ar, R. Bures, M. F aberov a, Design of novel soft magnetic composites based on Fe/resin modified with silica, Mater. Lett. 101 (2013) 37e40. [24] A. Aharoni, Demagnetizing factors for rectangular ferromagnetic prisms, J. Appl. Phys. 83 (1998) 3432e3434. [25] D.L, Z. Pei-heng, High frequency magnetic structure and magnetic bounds relation, J. Univ. Electron. Sci. Technol. China 38 (2009) 531e536. [26] W. Li, H. Cai, Y. Kang, Y. Ying, J. Yu, J. Zheng, L. Qiao, Y. Jiang, S. Che, High permeability and low loss bioinspired soft magnetic composites with nacrelike structure for high frequency applications, Acta Mater. 167 (2019) 267e274. [27] A. Calka, A.P. Radlinski, Universal high performance ball-milling device and its application for mechanical alloying, Mater. Sci. Eng. A 134 (1991) 1350e1353. [28] T.D. Zhou, P.H. Zhou, D.F. Liang, L.J. Deng, Structure and electromagnetic characteristics of flaky FeSiAl powders made by melt-quenching, J. Alloy. Comp. 484 (2009) 545e549. [29] Y. Haichen, FeSiAl magnetic powder prepared with strip cast and its
properties researching, J. Funct. Mater. 47 (1) (2016) 1180e1182. [30] W. Wei, M. Tianyu, L. Wei, et al., Microstructure and electromagnetic properties of Fe-Si-Al flakes produced from melt-spun ribbons, Rare Metal Mater. Eng. 37 (3) (2008) 513e516. [31] K. Yanagimoto, K. Majima, S. Sunada, et al., Effect of Si and Al content on core loss in Fe Si Al powder cores, Magn. IEEE Trans. 40 (3) (2004) 1691e1694. €ber, Arthur Fink, Ernst Bohn, Controlled growth of monodisperse [32] Werner Sto silica spheres in the micron size range, J. Colloid Interface Sci. 26 (1) (1968) 62e69. [33] M.G. Han, D.F. Liang, L.J. Deng, Analyses on the dispersion spectra of permeability and permittivity for NiZn spinel ferrites doped with SiO2, Appl. Phys. Lett. 90 (19) (2007), 192507. k, et al., A comprehensive complex permeability approach to soft mag[34] Doba netic bulk cores from pure or resin coated Fe and pulverized alloys at elevated temperatures, J. Alloy. Comp. 695 (2017) 1998e2007. k, et al., Temperature evolution of broadband magnetization behavior in [35] Doba dual-phase soft magnetic compacted materials, Mater. Des. 114 (2017) 383e390.
Please cite this article as: W. Li et al., Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy, Journal of Alloys and Compounds, https://doi.org/10.1016/j.jallcom.2019.153028
Contents lists available at ScienceDirect
Journal of Alloys and Compounds journal homepage: http://www.elsevier.com/locate/jalcom
Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy Wangchang Li a, Yang Zheng a, Yue Kang b, Ansar Masood c, Yao Ying a, Jing Yu a, Jingwu Zheng a, Liang Qiao a, Juan Li a, Shenglei Che a, * a b c
College of Materials Science and Engineering, Zhejiang University of Technology, Hangzhou, 310014, China School of Materials Science and Engineering, Tsinghua University, Beijing, 100084, China Microsystems Centre, Tyndall National Institute, University College Cork, Cork, Ireland
a r t i c l e i n f o
a b s t r a c t
Article history: Received 11 September 2019 Received in revised form 12 November 2019 Accepted 13 November 2019 Available online xxx
Herein, flake-like FeSiAl particles are prepared by rapid quenching and subsequent ball milling processes. Then, soft magnetic composites are fabricated by orderly aligned flake-like FeSiAl particles, resulting in the formation of nacre-like structure. The influence of processing parameters on columnar microstructure of the thin strips has been studied in detail. Furthermore, the magnetic permeability and loss of the soft magnetic composites, with different compositions, are explored. The results reveal that the soft magnetic composite, with flake-like Fe85Si9.6Al5.4, renders the magnetic permeability of 200 at 1 MHz, which is much higher than the spherical FeSiAl particles. Moreover, the negative temperature-dependent loss and a valley temperature of 65 C are observed at the Sendust composition of Fe85Si8.8Al6.2, which maintained the magnetic permeability of 172 at 1 MHz and a loss of 380 kW/m3 at 50 kHz (stimulated at 100 mT). It is worth emphasizing that the nacre-like SMC exhibits outstanding properties and renders promise for next-generation magnetic devices. © 2019 Elsevier B.V. All rights reserved.
Keywords: Rapidly quenched Nacre-like structure Flake-like FeSiAl alloy Complex permeability Temperature-dependent loss characteristics
1. Introduction Soft magnetic composites (SMC) are constructed by combining soft-magnetic metallic particles with insulating materials through the powder metallurgy route [1], followed by annealing at an optimal temperature [2]. In general, compared to the soft magnetic ferrite, soft magnetic metallic alloys, such as FeNi, FeSiAl, and FeCoNi [3], exhibit high saturation magnetization at the expense of resistivity, resulting in high eddy current loss at high frequency. Therefore, SMCs are employed to enhance the resistivity through the insulating boundary to reduce the eddy current loss and maintain high saturation magnetization, which is sorely required for next-generation semiconductor switching power supplies [1]. Moreover, the coating can be divided into two types: inorganic and organic insulants. However, the organic coatings, i.e., phenolic resin [4], are destroyed at high temperatures and, therefore, cannot be annealed. On the other hand, the inorganic coatings, such as FePO4 [5,6], MgO [7], SiO2 [8], Al2O3 [9], Fe3O4 [10], NiCuZn ferrite [11] and
* Corresponding author. E-mail address: [email protected] (S. Che).
MnZn ferrite [12], can be annealed at high temperatures. It is worth emphasizing that silica is a typical inorganic coating material, which is widely utilized in soft magnetic composites due to its high-temperature resistance [13,14]. In recent years, amorphous and non-crystalline particles have been developed for advanced devices [15,16]. SMCs are widely employed in electronic components due to their tunable magnetic permeability, high saturation magnetization and low magnetic loss [17,18]. However, the magnetic permeability of SMC, prepared by using spherical powders, is usually limited to 120 [19] and the applied frequency is usually lower than 100 kHz. One should note that the low magnetic permeability limits the practical utilization of SMCs in miniaturized devices, which implies that the development of SMCs, with superior magnetic permeability, is of utmost importance [20,21]. In fact, magnetic permeability and loss are related to the shape, dimension, and composition of particles [22,23]. According to Aharoni’s equation [24] and Snoek’s law [25], the relationship between permeability and the particle shape determines the demagnetization factor in different directions. Previously, our group has fabricated a nacre-like SMC [26] and demonstrated excellent permeability and low loss in the high-frequency regime.
https://doi.org/10.1016/j.jallcom.2019.153028 0925-8388/© 2019 Elsevier B.V. All rights reserved.
Please cite this article as: W. Li et al., Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy, Journal of Alloys and Compounds, https://doi.org/10.1016/j.jallcom.2019.153028
2
W. Li et al. / Journal of Alloys and Compounds xxx (xxxx) xxx
However, flake-like FeSiAl particles are difficult to obtain due to high hardness and brittleness of FeSiAl. Therefore, FeSiAl alloys are produced by either mechanical alloying or ball milling [27]. Rapid quenching is an efficient method of directly producing flake-like FeSiAl particles [28]. It has been reported that flake-like FeSiAl particles render superior performance due to their unique morphology. For instance, Haichen et al. [29] have studied the microstructural evolution of FeSiAl alloy during rapid quenching and demonstrated a fine-grained structure with superior saturation magnetization. Wei et al. [30] have synthesized flake-like FeSiAl alloy by rapid quenching method, which exhibited better electromagnetic properties. Hence, rapid quenching method can be utilized to fabricate flake-like alloy powder. On the other hand, FeSiAl alloy exhibits thermal failure behavior and the loss rapidly increases with increasing temperature, limiting the practical utilization of FeSiAl alloy in electronic devices due to the inevitable generation of heat and corresponding temperature increase during operation. Yanagimoto et al. [31] have observed the temperature-dependent magnetic behavior of FeSiAl SMC can be altered by tuning the content of Si and Al. Previously, we have reported the fabrication of SMCs by using metallic powders, however, the spherical morphology of the asprepared SMC rendered low permeability due to the effective anisotropy field, which is related to the shape of particles. Herein, we aimed to fabricate a soft magnetic lamellar composite by orderly aligning the flake-like FeSiAl particles, resulting in superior soft magnetic properties. The magnetic permeability of flake-like FeSiAl powder is significantly improved due to nacre-like structure. Moreover, different compositions of flake-like FeSiAl powder have been fabricated by rapid quenching, and the influence of process parameters on morphological evolution has been systematically investigated. Furthermore, we have explored the magnetic properties of as-prepared FeSiAl powder and the nacrelike magnetic ring. The nacre-like SMC exhibits promise for the future development of miniaturized magnetic devices. 2. Experimental section 2.1. Strip fabrication. (Melting and quenching) First, high purity metals, i.e., Fe (99%), Si (99%) and Al (99%), were melted to form an alloy ingot under argon atmosphere. Four different compositions of FeSiAl alloy, i.e., Fe85Si8Al7, Fe85Si8.8Al7.2, Fe85Si9.6Al5.4, and Fe85Si11Al4, were prepared by adjusting the ratio of different metals. Then, FeSiAl ribbon (~20 mm) was obtained by the rapid quenching method. Briefly, FeSiAl alloy ingot was placed in a quartz tube and the chamber is evacuated to <103 Pa. Then, the argon gas was filled into the chamber to reach a pressure of 50 Pa. The quartz tube was placed in the middle of a heating coil. Then, the current was slowly adjusted to 25 A for heating and the molten metal from the quartz tube was sprayed on a high-speed rotating copper (Cu) wheel. The molten metal was rapidly solidified and detached from the Cu wheel to obtain a thin strip. The asobtained thin strips of FeSiAl alloy were annealed at 700 C for 2 h. 2.2. Powder synthesis The as-prepared FeSiAl alloy strips were ball milled to further reduce the thickness of Sendust particles to achieve a low loss in the high-frequency regime. Briefly, 1000 g of hard steel balls and thin strip were added into a grinding jar with an appropriate amount of ethanol and the BPR was 50:1. Moreover, 35 wt % glycerol was added to control the viscosity of the solution. The ball milling was carried out for 4 h, and the as-received FeSiAl particles were dried in a vacuum oven at 60 C, followed annealing at 700 C
in a nitrogen atmosphere. 2.3. Fabrication of magnetic ring Furthermore, the flake-like FeSiAl powder was coated by using € ber coating method [32]. In a typical process, a certain amount Sto of FeSiAl powder was mixed with deionized water and absolute ethanol solution, followed by ultrasonic dispersion for 15 min. Then, 0.125 mL of NH3$H2O solution was slowly added and stirred for 30 min, followed by the addition of 0.25 mL of TEOS and stirring at 30 C for 4 h. Finally, the coated powder was rinsed with absolute ethanol and vacuum dried at 60 C. Moreover, a lubricant (0.3% zinc stearate) was mixed into the powder. Then, FeSiAl powder was layer-by-layer compacted under a pressure of 1200 MPa to prepare a magnetic ring with an outer diameter of 12.7 mm, an inner diameter of 7.6 mm and a thickness of 2 mm. The as-prepared magnetic ring was annealed at 700 C for 4 h. 2.4. Characterization The microscopic structure was observed by using a scanning electron microscope (SEM, Hitachi SU1510). X-ray diffraction (XRD, PANalytical X’Pert PRO X) was employed to investigate the crystal structure. The permeability of the magnetic ring was measured at room temperature in the frequency range of 1 MHz to 1 GHz by using an RF impedance analyzer (Agilent E4991). Hysteresis loop and loss were measured by using a vibrating sample magnetometer (VSM, Lake Shore 7410) and a BeH analyzer (SY-8218, IWATSU). The electrical resistivity was measured by using four-point probe (RTS8). 3. Results and discussion 3.1. Structural and morphological characterization It is worth noting that the rotational speed of the Cu wheel during the rapid quenching process significantly influenced the microstructure of magnetic ribbon. At low rotational speed, the heat is effectively transferred from the molten alloy to the Cu wheel, providing sufficient time for nucleation and growth of FeSiAl alloy on Cu wheel. However, at a high rotational speed, the finegrained structure is observed due to the faster cooling process. As shown in Fig. 1b, the thickness of the ribbon at a rotational velocity of 48 m s1 was ~20 mm. On the other hand, the thickness of the ribbon at a rotational velocity of 32 m s1 was ~45 mm. The XRD patterns of FeSiAl alloys, prepared at different rotational velocities, are presented in Fig. 2. At a rotational velocity of 8 m s1, the diffraction peaks of (200) and (400) planes of FeSiAl alloy are stronger than the samples prepared at higher rotational velocities, such as 48 m s1, whereas the diffraction peak of (422) planes is weaker. XRD results reveal the oriented growth of crystal grains. At lower rotational speed, the grain growth occurred along the (400) planes of FeSiAl alloy, whereas (220) and (422) planes became dominant with increasing rotational speed. One should note that the grain growth is initiated with the solidification of molten metal and the high rotational speed suppresses the grain growth in certain planes due to the insufficient nucleation time. 3.2. Characterization of the magnetic powder The flake-like FeSiAl powder, with a transverse diameter of 50 mm, has been successfully fabricated after ball milling, as shown in Fig. 3. Moreover, FeSiAl alloy exhibited a disordered body center cubic (BCC) and ordered DO3 structure, where (220), (400), (422) peaks belong to BCC phase and (111), (200) and (311) peaks
Please cite this article as: W. Li et al., Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy, Journal of Alloys and Compounds, https://doi.org/10.1016/j.jallcom.2019.153028
W. Li et al. / Journal of Alloys and Compounds xxx (xxxx) xxx
3
Fig. 1. The cross-sectional SEM images of the magnetic ribbon at a rotational speed of (a) 32 m s1 and (b) 48 m s1.
the diffraction peak, corresponding to (111) planes, became obvious after ball milling, which can be ascribed to the formation of DO3 phase due to the occupation of Fe sites by Si and Al atoms in the aFe lattice. The hysteresis loops of different compositions of FeSiAl powder are obtained by using a vibrating sample magnetometer (VSM), and the results are shown in Fig. 4. At 25 C, the hysteresis loop did not exhibit any significant change with respect to composition and different compositions of FeSiAl powder rendered soft magnetic properties. Moreover, the Ms values of Fe85Si8Al7, Fe85Si8.8Al7.2, Fe85Si9.6Al5.4, and Fe85Si11Al4 alloys were found to be 119.4 emu$g1, 120.96 emu$g1, 113.86 emu$g1 and 117.97 emu$g1, respectively. On the other hand, the coercive force has been significantly altered with compositional variations. In general, the coercivity is decreased with increasing Si content. Hence, Fe85Si8Al7 and Fe85Si11Al4 alloy exhibited coercivity values of 41.75 Oe and 21.97 Oe, respectively. Fig. 2. XRD pattern of FeSiAl alloy, prepared at different rotational velocities.
correspond to the ordered DO3 phase. After rapid quenching, BCC structure has been observed as the main phase, which is indicated by the presence of (220) and (400) peaks. Moreover, both Al and Si occupy the Fe sites during rapid quenching, resulting in a thin band with an ordered phase. Moreover, the ordered phase disappeared after ball milling, resulting in the appearance of (110), (200) and (211) peaks. One should note that the ball milling process induced dislocations and defects in FeSiAl particles, increasing the energy of alloy constituents. Hence, Si and Al atoms are separated from the a-Fe lattice, rendering a completely disordered structure. However, after annealing at 700 C, ordered DO3 phase re-emerged, as evidenced by strong (111) and (200) diffraction peaks. It is worth noting that
3.3. Magnetic properties and loss of SMC Fig. 5 presents the morphology of flake-like FeSiAl-coated SiO2 and the microstructure of the magnetic core. It can be readily observed that a thin layer of SiO2 is formed on the surface of flakelike FeSiAl powder and the sheet-like FeSiAl formed an ordered structure of layered stacks. Moreover, the SiO2 coating layer is observed between the flakes, which is similar to the brick-mud structure of the shell. Table 1 shows the resistivity of different samples, and the resistivity is closely related to loss. The excellent properties of FeSiAl are only in a small composition range, and the resistivity of Fe85Si8Al7 is 32.5 U m, which is far below that of the Fe85Si8.8Al6.2 and Fe85Si9.6Al5.4. This may be the reason for the high loss of the Fe85Si8Al7 sample. The loss of FeSiAl is extremely sensitive to composition. When the composition in FeSiAl deviates too much
Fig. 3. (a) SEM image of FeSiAl particles after ball milling and (b) XRD patterns of FeSiAl alloys during different preparation stages.
Please cite this article as: W. Li et al., Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy, Journal of Alloys and Compounds, https://doi.org/10.1016/j.jallcom.2019.153028
4
W. Li et al. / Journal of Alloys and Compounds xxx (xxxx) xxx
Fig. 4. (a) Hysteresis loops and (b) magnetic properties of different compositions of FeSiAl powder, where blue and red columns represent the saturation magnetization and coercivity. (For interpretation of the references to colour in this figure legend, the reader is referred to the Web version of this article.)
Fig. 5. (a) The morphology and (b) cross-sectional SEM image of flake-like sendust@SiO2 particles, where (b) shows the nacre-like structure.
Table 1 Resistivity of different samples. Component
Fe85Si8Al7
Fe85Si8.8Al6.2
Fe85Si9.6Al5.4
Fe85Si11Al4
Resistivity (Um)
32.5
83.1
87.9
48.42
from Fe85Si9.6Al5.4, the performance changes greatly, as Fe85Si8Al7 and Fe85Si11Al4, in which the resistivity reduced from 87.9 U m to 32.5 U m and 48.42 U m, respectively. Fig. 6 shows the magnetic permeability of different compositions of FeSiAl at high frequency. The real magnetic permeability of the sheet-like FeSiAl powder core reached a value of 200 in the frequency range of 1e1000 MHz, which is far higher than the traditional SMCs. According to the theory [33], two resonance peaks should be observed in the imaginary part of the magnetic permeability curve, which is mainly related to the composition of the magnetic spectrum. One should note that the magnetic
spectrum is mainly composed of the domain wall resonance and spin resonance, where the spin resonance is related to the ferromagnetic resonance and the magneto crystalline anisotropy field. But now there is only one resonance being observed. It should be that the spin resonance component affects much more than the domain wall component. It has been observed that a change in alloy composition significantly deteriorated the magnetic properties of the composites. For instance, when the alloy composition significantly deviates from Fe85Si9.6Al5.4, the magnetic permeability is rapidly decreased and exhibited a value of 100, which is almost half of the magnetic permeability of Fe85Si9.6Al5.4. However, the slight deviation from Fe85Si9.6Al5.4 resulted in small change in magnetic permeability. For instance, Fe85Si9.6Al5.4 exhibited a magnetic permeability of 172. Furthermore, the loss characteristic of Fe85Si8.8Al6.2 is similar to ferrite, and a valley temperature is observed at 65 C. In the case of Fe85Si8Al7, the loss exhibited a negative temperature-dependent
Fig. 6. (a) The frequency-dependent complex permeability and (b) temperature-dependent loss of different compositions of FeSiAl alloy.
Please cite this article as: W. Li et al., Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy, Journal of Alloys and Compounds, https://doi.org/10.1016/j.jallcom.2019.153028
W. Li et al. / Journal of Alloys and Compounds xxx (xxxx) xxx
behavior, which can be ascribed to the relationship between the magnetic crystal coefficients and Si content. Moreover, an extremely high value of which loss has been observed at 25 C, which decreased with increasing temperature. In the case of Fe85Si9.6Al5.4, the loss linearly increased with increasing temperature due to the decrease in resistivity, resulting in an increased eddy current loss. One should note that the magnetic crystal coefficient K and magnetostriction coefficient are related to the Si content, indicating the difficulty of magnetic domain movement. Moreover, magnetic crystal coefficients and magnetostriction coefficient are closely related to the temperature dependence of the loss. At the Si content of 9.6 wt % and K > 0, the loss has exhibited a positive relationship with temperature, whereas, at the Si content of 8 wt % and K < 0, the loss has exhibited a negative temperature dependence. At the Si content of 8.8 wt % and K ¼ 0, a valley temperature occurs, where the magnetic domain is most likely to move. On the other hand, the magnetostriction coefficient has exhibited an opposite trend. Apart from the magnetic crystal coefficient magnetostriction coefficient, it can explain from the study of Samuel Dob ak et al. [34,35], domain walls motion and magnetization rotation were closely related to loss. When the temperature rised, mechanical stresses were relieved and the anisotropy reduction, resulting in reduced sample loss.
4. Conclusions In summary, FeSiAl thin strips have been successfully fabricated by a rapid quenching method. The thickness of the magnetic ribbon decreased with increasing the rotation speed of Cu wheel. Once the rotation speed of Cu wheel is increased from 32 m s1 to 48 m s1, the thickness of the magnetic ribbon decreased from 45 mm to 20 mm. Moreover, preferential grain growth has been observed after rapid quenching, where the grain growth is initiated along (422) planes, followed by (200) and (400) planes. In addition, ordered DO3 phase reappeared after annealing at 700 C. Furthermore, a high magnetic permeability (u’ ¼ 200 at 1 MHz) is obtained by uniformly mixing the rapidly quenched Fe85Si9.6Al5.4 with SiO2. Moreover, the loss behavior has been influenced by compositional changes. In general, the loss is linearly increased with increasing temperature. At 0 C, Fe85Si9.6Al5.4-containing SMC rendered a loss of 313.5 kW/m3, which increased to 413.77 kW/m3 at 65 C. In the case of Fe85Si8.8Al6.2, the loss curve exhibited a similar trend with ferrite, i.e., the loss decreased with increasing temperature till a valley temperature (~65 C), resulting in a loss value of 380 kW/m3 and magnetic permeability of 172 at 1 MHz Moreover, the loss has exhibited a negative temperature dependence in the case of Fe85Si8Al7, resulting in a loss value of 571.84 kW/m3 at 145 C.
Author contributions Wangchang Li: Conceptualization, Methodology, Writing Original Draft, Writing - Review & Editing. Yang Zheng: Methodology, Data Curation, Investigation. Yue Kang: Writing - Review & Editing. Ansar Masoodc: Writing - Review & Editing. Yao Ying: Writing - Review & Editing. Jing Yu: Writing - Review & Editing. Jingwu Zheng: Writing - Review & Editing. Liang Qiao: Writing - Review & Editing. Juan Li: Writing - Review & Editing. Shenglei Che: Resources, Supervision, Project administration.
5
Declaration of competing interest Neither the entire paper nor any part of its content has been published or accepted elsewhere. It is not being submitted to any other journal. All authors (Wangchang Li, Yang Zheng, Yue Kang, Ansar Masood, Yao Ying, Jing Yu, Jingwu Zheng, Liang Qiao, Juan Li, Shenglei Che) approve to submit the manuscript to your journal. The authors declare that they do not have any conflict of interest. Acknowledgements This work was supported by National Nature Science Foundation of China through Grant No.51602283 and No. 11404397. References [1] H. Shokrollahi, K. Janghorban, Soft magnetic composite materials (SMCs), J. Mater. Process. Technol. 189 (2007) 1e12. [2] W. Li, Z. Wang, In-situ formation of Fe3O4 and ZrO2 coated Fe-based soft Magnetic Composites by hydrothermal method, Ceram. Int. 45 (2019) 3864e3870. [3] M. Persson, Development in soft magnetic components, Met. Powder Rep. 55 (2000) 10e11. [4] M.M. Dias, H.J. Mozetic, J.S. Barboza, et al., Influence of resin type and content on electrical and magnetic properties of soft magnetic composites (SMCs), Powder Technol. 237 (2013) 213e220. [5] A.H. Taghvaei, H. Shokrollahi, K. Janghorban, Prope rties of iron-based soft magnetic composite with iron phosphateesilane insulation coating, J. Alloy. Comp. 481 (2009) 681e686. [6] D.Z. Xie, K.H. Lin, S.T. Lin, Effects of processed parameters on the magnetic performance of a powder magnetic core, J. Magn. Magn. Mater. 353 (2014) 34e40. [7] A.H. Taghvaei, A. Ebrahimi, M. Ghaffari, K. Janghorban, Magnetic properties of iron -based soft magnetic composites with Mgo coating obtained by solegel method, J. Magn. Magn. Mater. 322 (2010) 808e813. [8] S. Wu, A. Sun, Z. Lu, C. Cheng, X. Gao, Magnetic properties of iron -based soft magnetic composites with SiO2 coating obtained by reverse microemulsion method, J. Magn. Magn. Mater. 381 (2015) 451e456. [9] M. Yaghtin, A.H. Taghvaei, B. Hashemi, K. Janghorban, Effect of heat treatment on magnetic properties of iron-based soft magnetic composites with Al2O3 insulation coating produced by solegel method, J. Alloy. Comp. 58 (2013) 293e297. [10] J. Li, J. Yu, W. Li, S. Che, J. Zheng, L. Qiao, Y. Ying, The preparation and magnetic performance of the iron-based soft magnetic composites with the Fe@Fe3O4 powder of in situ surface oxidation, J. Magn. Magn. Mater. 454 (2018) 103e109. [11] W. Li, W. Wang, J. Lv, Y. Ying, J. Yu, J. Zheng, L. Qiao, S. Che, Structure and magnetic properties of iron-based soft magnetic composite with Ni-Cu-Zn ferriteesilicone insulation coating, J. Magn. Magn. Mater. 456 (2018). [12] S. Wu, A. Sun, W. Xu, Q. Zhang, F. Zhai, P. Logan, A.A. Volinsky, Iron -based soft magnetic composites with MneZn ferrite nanoparticles coating obtained by solegel method, J. Magn. Magn. Mater. 324 (2012) 3899. [13] B. Yang, Z. Wu, Z. Zou, R. Yu, High -performance Fe/SiO2 soft magnetic composites for low and high-power applications, J. Phys. D Appl. Phys. 43 (2010). [14] Y.W. Zhao, X. Zhang, J. Xiao, Submicrometer lami nated Fe/SiO2 soft magnetic compositesdan effective route to materials for high- frequency applications, Adv. Mater. 17 (2010) 915e918. [15] D.H. Ping, Y.Q. Wu, K. Hono, M.A. Willard, M.E. Mchenry, D.E. Laughlin, Microstructural characterization of (Fe0.5Co0.5)88Zr7B4Cu1 nanocrystalline alloys, Scr. Mater. 45 (2001) 781e786. [16] M.A. Willard, D.E. Laughlin, M.E. Mchenry, D. Thoma, K. Sickafus, J.O. Cross, V.G. Harris, Structure and magnetic properties of (Fe0.5Co0.5)88Zr7B4Cu1 nanocrystalline alloys, J. Appl. Phys. 84 (1998) 6773e6777. [17] A. Ozols, M. Pagnola, D.I. García, H. Sirkin, Electroless coating of Permalloy powder and DC-resistivity of alloy composites, Surf. Coat. Technol. 200 (2006) 6821e6825. D a , S. Dob kov berova , R. Bures, [18] J. Füzer, M. Stre ckova ak, L. a, P. Koll ar, M. Fa Y. Osadchuk, P. Kurek, M. Vojtko, Innovative ferrite nanofibres reinforced soft magnetic composite with enhanced electrical resistivity, J. Alloy. Comp. 753 (2018) 219e227. [19] J. Li, X. Peng, Y. Yang, H. Ge, Preparation and characterization of MnZn/FeSiAl soft magnetic composites, J. Magn. Magn. Mater. 426 (2017) 132e136. [20] M.L. Tuballa, M.L. Abundo, A review of the development of Smart Grid technologies, Renew. Sustain. Energy Rev. 59 (2016) 710e725. [21] B. Zhao, Q. Song, W. Liu, et al., Overview of dual-active-bridge isolated bidirectional DCeDC converter for high-frequency-link power-conversion system, IEEE Trans. Power Electron. 29 (2014) 4091e4106. [22] S. Yoshida, M. Sato, E. Sugawara, Y. Shimada, Permeability and electromagnetic-interference characteristics of Fe-Si-Al alloy flakes-polymer
Please cite this article as: W. Li et al., Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy, Journal of Alloys and Compounds, https://doi.org/10.1016/j.jallcom.2019.153028
6
W. Li et al. / Journal of Alloys and Compounds xxx (xxxx) xxx
composite, J. Appl. Phys. 85 (1999) 4636e4638. [23] M. Stre ckov a, L. Medvecký, J. Füzer, P. Koll ar, R. Bures, M. F aberov a, Design of novel soft magnetic composites based on Fe/resin modified with silica, Mater. Lett. 101 (2013) 37e40. [24] A. Aharoni, Demagnetizing factors for rectangular ferromagnetic prisms, J. Appl. Phys. 83 (1998) 3432e3434. [25] D.L, Z. Pei-heng, High frequency magnetic structure and magnetic bounds relation, J. Univ. Electron. Sci. Technol. China 38 (2009) 531e536. [26] W. Li, H. Cai, Y. Kang, Y. Ying, J. Yu, J. Zheng, L. Qiao, Y. Jiang, S. Che, High permeability and low loss bioinspired soft magnetic composites with nacrelike structure for high frequency applications, Acta Mater. 167 (2019) 267e274. [27] A. Calka, A.P. Radlinski, Universal high performance ball-milling device and its application for mechanical alloying, Mater. Sci. Eng. A 134 (1991) 1350e1353. [28] T.D. Zhou, P.H. Zhou, D.F. Liang, L.J. Deng, Structure and electromagnetic characteristics of flaky FeSiAl powders made by melt-quenching, J. Alloy. Comp. 484 (2009) 545e549. [29] Y. Haichen, FeSiAl magnetic powder prepared with strip cast and its
properties researching, J. Funct. Mater. 47 (1) (2016) 1180e1182. [30] W. Wei, M. Tianyu, L. Wei, et al., Microstructure and electromagnetic properties of Fe-Si-Al flakes produced from melt-spun ribbons, Rare Metal Mater. Eng. 37 (3) (2008) 513e516. [31] K. Yanagimoto, K. Majima, S. Sunada, et al., Effect of Si and Al content on core loss in Fe Si Al powder cores, Magn. IEEE Trans. 40 (3) (2004) 1691e1694. €ber, Arthur Fink, Ernst Bohn, Controlled growth of monodisperse [32] Werner Sto silica spheres in the micron size range, J. Colloid Interface Sci. 26 (1) (1968) 62e69. [33] M.G. Han, D.F. Liang, L.J. Deng, Analyses on the dispersion spectra of permeability and permittivity for NiZn spinel ferrites doped with SiO2, Appl. Phys. Lett. 90 (19) (2007), 192507. k, et al., A comprehensive complex permeability approach to soft mag[34] Doba netic bulk cores from pure or resin coated Fe and pulverized alloys at elevated temperatures, J. Alloy. Comp. 695 (2017) 1998e2007. k, et al., Temperature evolution of broadband magnetization behavior in [35] Doba dual-phase soft magnetic compacted materials, Mater. Des. 114 (2017) 383e390.
Please cite this article as: W. Li et al., Magnetic behavior of soft magnetic composites constructed by rapidly quenched flake-like FeSiAl alloy, Journal of Alloys and Compounds, https://doi.org/10.1016/j.jallcom.2019.153028