Permalloy/alumina soft magnetic composite compacts obtained by reaction of Al-permalloy with Fe2O3 nanoparticles upon spark plasma sintering

Composite sintered soft magnetic materials of permalloy/alumina type have been obtained by reactive spark plasma sintering. The composite compacts have been obtained by sintering of Ni71.25Fe23.75Al5 alloy with 3 and 5% (wt.) Fe₂O₃ nanoparticles. The Ni based alloy with large particles (up to hundreds of μm) have been covered by a thin layer of iron ferric oxide nanoparticles (20–40 nm). The as obtained composite particles have been subjected to sintering process using a homemade installation at 900 °C for 10 min. Upon sintering process several reactions between Ni-based alloy and iron oxide are induced, the main phase resulting from reaction is alumina-Al₂O₃ as it results by X-ray diffraction investigations. According to the scanning electron microscopy and energy dispersive X-ray spectroscopy investigations, alumina forms a matrix embedding the Ni-based particles. The alumina matrix is continuous, but the layer has large variation in width, and offers a high electrical resistivity. A mechanism of formation is proposed for the alumina matrix composite compacts when using Al-permalloy powder and iron oxide. The compacts have been tested in DC and AC for magnetic characteristics.