Fe-Based Amorphous Magnetic Powder Cores with Low Core Loss Fabricated by Novel Gas-Water Combined Atomization Powders

FeSiBCCr amorphous powders were produced by a novel gas-water combined atomization process, and the corresponding MPCs (magnetic powder cores) were subsequently fabricated by phosphating treatment (0.4 similar to 1.6 wt.%), cold pressing (550 similar to 2350 MPa), and annealing (423 similar to 773 K), respectively. The results showed that the powders had high circularity, excellent thermal stability (Delta T = 59 K), and high saturation magnetization (0.83 T), which could provide raw powders for high-performance MPCs. With increasing phosphoric acid concentrations, despite the increase in DC-bias%, the uniformity of the insulation layers deteriorated, which led to a decrease in permeability and an increase in core loss. With increasing compaction pressures, the core loss increased continuously, and the permeability and DC-bias% first increased and then decreased. When annealing below the crystallization temperature, with increasing annealing temperatures, the permeability increased, and the core loss and DC-bias% decreased continuously. Under the optimized process of 0.4 wt.% phosphating concentration, 550 MPa pressure, and 773 K annealing temperature, the MPCs had a permeability of 21.54 +/- 1.21, DC-bias% of 90.3 +/- 0.2, and a core loss (B-m = 50 mT,f = 100 kHz) of 103.0 +/- 26.3 mW cm(-3). The MPCs had excellent high-frequency low-loss characteristics and showed great application potential under the development trends of high current, high power, and high frequency of electronic components.