Soft magnetic materials such as FeNi and FeCo alloys are crucial in various applications due to their high permeability and low coercivity. In this research, ultrasonic atomization was investigated as a novel approach for producing high-quality, spherical soft magnetic powders with a controlled particle size distribution. Pre-forms were manufactured using conventional press-and-sinter methods, producing novel alloy compositions tailored to enhance magnetic properties and address limitations of commercially available powders. Powder characterization was performed using SEM and XRD, alongside analyses of phase formation and magnetic properties. Theoretical calculations, including CALPHAD for phase stability predictions provided insights into the atomization process. The results demonstrate the suitability of ultrasonic atomization for producing small batches of highly spherical powders with customizable properties, highlighting its potential to advance research and development in soft magnetic materials.
Nahringbauer et al. (Thu,) studied this question.