Enhanced high frequency properties of FeSiBPC amorphous soft magnetic powder cores with novel insulating layer

Fe-based amorphous magnetic powder cores (AMPCs) with excellent comprehensive properties were successfully fabricated via using the uniform double insulating layer core-shell structured FeSiBPC/Fe₃O₄@Epoxy resin (EP). The effects of the in-situ hydrothermal oxidized time on the magnetic properties of the AMPCs have been systematically investigated on the basis of the growth mechanism of the insulating layer of spherical amorphous powder in alkaline environment. The hydrothermal oxidation process could well ensure the uniformity of the oxide layer composed of Fe₃O₄ nanoparticle. The evolution of the insulating layer is a process of homogeneous nucleation and growth at different hydrothermal oxidation time. After 10 h of hydrothermal oxidation, a thin and dense layer composed of Fe₃O₄ nanoparticle was formed on the surface of the amorphous powder. As a consequent, the FeSiBPC AMPCs exhibit excellent performance such as stable effective permeability of 49.5 at 2 MHz, a very low core loss of 187 mW/cm³ at 100 kHz@0.05 T and high-quality factor of 160 at 600 kHz. The results indicate that the thickness of the Fe₃O₄ insulating layer can be completely controlled via the reaction parameters, and can effectively suppress the eddy current loss, which is promising for high-frequency electromagnetic systems.