Preparation and magnetic properties of novel hybrid magnetic powder cores

Magnetic powder cores are an important kind of soft magnetic materials that are widely used in various electrical and magnetic devices. In this work, high performance hybrid magnetic powder cores have been prepared by compacting silicon resin coated soft magnetic composite (SMC) powders. The SMC powders are obtained from mixing suitable proportions of FeSi and FeNi powders uniformly with pure iron powders. A high density of over 7·27 g cm−3 can be obtained in hybrid magnetic powder cores. The core loss of the magnetic cores prepared from mixing 90 wt-%Fe and 10 wt-%FeSi powders measured at a frequency of 50 Hz and an induction level of 1 T is 7·5 W kg−1, which is much lower than that of pure iron powder cores (8·4 W kg−1), and their magnetic induction measured at an induction level of 10 kA m−1 is 1·38 T, which is higher than that of pure iron powder cores (1·34 T).