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FeSiCr及Fe基非晶/纳米晶软磁复合材料绝缘包覆研究进展

Research progress on insulating coating of FeSiCr and Fe-Based amorphous/nanocrystalline soft magnetic composites

  • 摘要: 软磁复合材料因其优异的高频低损耗特性和三维成形能力,已成为高频电力电子领域的关键材料。FeSiCr、铁基非晶/纳米晶软磁复合材料是目前主流的软磁复合材料,绝缘包覆技术作为其核心工艺环节,直接决定了其电阻率、磁导率、损耗及力学稳定性等综合性能。系统综述了三类合金粉成分设计、制备工艺及应用适配性,重点梳理了对应软磁复合材料无机、有机与无机-有机复合包覆方法的材料体系、工艺路径及其对微观结构与宏观性能的影响机制。通过对比不同包覆层在涡流抑制、热稳定增强与界面结合方面的作用,揭示了包覆层厚度、均匀性与磁性能之间的非线性耦合关系。同时,介绍了常用表征手段在包覆效果评估中的应用,为高性能SMCs材料的工程化开发提供了理论基础与技术参考。

     

    Abstract: Soft magnetic composites (SMCs) have emerged as critical materials in high-frequency power electronics due to their superior high-frequency low-loss characteristics and three-dimensional formability. Among them, FeSiCr and Fe-based amorphous/nanocrystalline soft magnetic composites represent the current mainstream systems. As a core processing step, the insulating coating technology directly determines their comprehensive properties, including electrical resistivity, permeability, core losses, and mechanical stability. This review systematically examines the compositional design, fabrication processes, and application-specific adaptability of three categories of alloy powders, with a focused analysis of inorganic, organic, and hybrid inorganic-organic coating methodologies for corresponding SMCs. It further elaborates on material systems, processing routes, and their underlying mechanisms governing microstructure evolution and macroscopic performance. By comparing the effects of various coatings on eddy current suppression, thermal stability enhancement, and interfacial bonding, we reveal the nonlinear coupling relationships among coating thickness, uniformity, and magnetic properties. Additionally, we introduce advanced characterization techniques for evaluating coating effectiveness, offering theoretical foundations and technical references for the engineered development of high-performance SMCs.

     

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