Herein, we address the challenge of high core losses in soft magnetic composites (SMCs) at high frequencies by developing a FeSiAl/WS
2 composite system processed under a transverse magnetic field (TMF). In this study, 200- and 600-mesh FeSiAl powders were used as base
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Herein, we address the challenge of high core losses in soft magnetic composites (SMCs) at high frequencies by developing a FeSiAl/WS
2 composite system processed under a transverse magnetic field (TMF). In this study, 200- and 600-mesh FeSiAl powders were used as base materials and combined with 2.25 wt.% two-dimensional tungsten disulfide (WS
2; an insulating agent) to prepare FeSiAl/2.25 wt.%WS
2 soft magnetic composites via ultrasonic mixing. The evolution of soft magnetic properties under a transverse magnetic field (TMF) was systematically investigated. The novelty of this work lies in the synergistic combination of fine FeSiAl particles and WS
2 nanosheets as an interparticle insulator and the application of a TMF to simultaneously suppress eddy current and hysteresis losses—a challenge that is difficult to address using conventional approaches. Morphological analysis confirmed a uniform and continuous organic coating of WS
2 nanosheets on FeSiAl particle surfaces. Permeability measurements revealed a slight decrease in effective permeability after the TMF treatment; however, the high-frequency performance was markedly enhanced. Magnetic loss analysis revealed a substantial reduction in the hysteresis loss and an increase in the quality factor under the TMF. Notably, the FeSiAl (600 mesh)/2.25 wt.% WS
2 composite achieved a total magnetic loss of 234 kW/m
3 under a TMF of 140 kA/m, magnetic induction of 20 mT, and frequency of 1 MHz, representing a 69% reduction compared with conventional SMCs. These results not only validate the effectiveness of the proposed synergistic approach but also highlight the potential of FeSiAl (600 mesh)/2.25 wt.% WS
2 for use in high-power, high-frequency magnetic devices, with improved energy efficiency and thermal performance.
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