High-frequency FeSiAl-based soft magnetic composites via simultaneously suppressed eddy and hysteresis losses Article Swipe
YOU?
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· 2025
· Open Access
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· DOI: https://doi.org/10.1038/s41467-025-64794-0
· OA: W4415660314
Soft magnetic composites present promising solutions for integrated transformers and inductors, but challenges arise at MHz range, where hysteresis and intra-eddy losses result in substantial performance degradation. In this study, we propose a bulk/interface insulation strategy to synthesize FeSiAl:Sn/Al 2 O 3 soft magnetic composite by mutual diffusion of metal atoms, where a ~ 3 um-depth Sn-substituted FeSiAl is obtained in the matrix and an insulating Al 2 O 3 layer is epitaxially grown on FeSiAl surface. The formation of FeSiAl:Sn can not only suppress intra-eddy loss by enhancing electrical resistivity, but also reduce coercivity by mitigating lattice distortion for reducing hysteresis loss. Meanwhile, the in-situ grown Al 2 O 3 layer can reduce inter-eddy loss by electrical isolation between FeSiAl particles. This construction leads to power loss of 47 mW/cm 3 at 100 kHz and 1344 mW/cm 3 at 1 MHz under 50 mT, as well as effective permeability of 60 up to tens of MHz, associated with cut-off frequency of 250.7 MHz. This approach lays the groundwork for the development of high-frequency soft magnetic composites in engineering applications.
