Soft magnetic materials are crucial in motors, generators, transformers, and many electronic devices. We synthesized the FeSi soft magnetic composites (SMCs) with different doping contents of Fe
2O
3 nanopowders as fillers via the hot-press sintering technique. This work explores the incorporation
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Soft magnetic materials are crucial in motors, generators, transformers, and many electronic devices. We synthesized the FeSi soft magnetic composites (SMCs) with different doping contents of Fe
2O
3 nanopowders as fillers via the hot-press sintering technique. This work explores the incorporation of high-resistivity magnetic fillers through a novel compaction technique and investigates the influence of Fe
2O
3 nanopowder on the structure and magnetic properties of Fe
2O
3 nanopowder-filled composites. The finding reveals that Fe
2O
3 nanopowders effectively fill the air gaps between FeSi powders, increasing SMC density. Moreover, all samples exhibit excellent effective permeability frequency stability, ranging from 15 kHz to 100 kHz. Notably, the effective permeability
µe improves from 22.32 to 30.45, a 36.42% increase, when the Fe
2O
3 doping concentration increases from 0 to 2 wt%. Adding Fe
2O
3 nanopowders also enhances electrical resistivity, leading to a 37.21% reduction in eddy current loss in samples for 5 wt% Fe
2O
3 addition, compared to undoped samples. Furthermore, as Fe
2O
3 content increases from 0 to 5 wt%, the power loss
Pcv of the Fe
2O
3-doped Fe-6.5Si SMCs decreases from 25.63 kW/m
3 to 16.13 kW/m
3, a 37% reduction. These results suggest that Fe
2O
3-doped FeSi SMCs, with their superior soft magnetic properties, hold significant potential for use in high-power and high-frequency electronic applications.
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