The Fe79Si8B13 and Fe75Si8B13Nb3Cu1 powder prepared by gas-water two-phase coupled rapid-setting sedimentation atomization (WGC)

To satisfy the reliability and magnetic property requirements of surface mounted devices (SMD), the high-performance Fe79Si8B13 and Fe75S8iB13Nb3Cu1 powders were prepared by gas-water two-phase coupled rapid-setting sedimentation atomisation technology (WGC). They were compared with the Fe79Si8B13 and Fe75S8iB13Nb3Cu1 powders prepared by the traditional water-gas combined atomisation technology (W-G). The result shows that the morphology of the Fe79Si8B13 and Fe75S8iB13Nb3Cu1 powders prepared by the WGC device is better. The defects, such as burrs and protrusions on the surface of powder particles, were removed, and the formed powders were almost entirely spherical. Through x-ray diffraction (XRD), transmission electron microscopy (TEM), differential scanning calorimetry (DSC), and vibrating sample magnetometer (VSM) analyses, we concluded that the Fe79Si8B13 and Fe75S8iB13Nb3Cu1 raw powder developed by the WGC device exhibited higher amorphousness and magnetic properties. Therefore, the novel WGC device exhibits a higher cooling capacity while preparing amorphous and nanocrystalline powders. It is also more suitable for the commercial production of amorphous and nanocrystalline powders. The magnetic properties of the powder were further evaluated by preparing them into a powder core. The powder developed by the WGC device with higher permeability can achieve similar direct current (DC) bias characteristics under higher permeability and lower core losses. These advantages of magnetic properties were pursued via SMD.