Search Results (28)

This study explores the crystal structure, microstructure and magnetic phase evolution of the AlCoCrFeNi high-entropy alloy (HEA), highlighting its potential for applications requiring tailored magnetic properties across diverse temperatures. Electron microscopy and X-ray diffraction revealed that the as-cast alloy’s microstructure comprises equiaxed grains with branching dendrites, showing compositional variations between interdendritic regions enriched in Al and Ni. Temperature-induced phase transformations were observed above room temperature, transitioning from body centered cubic (BCC) phases (A2 and B2) to a predominant FCC phase at higher temperatures, followed by recrystallization of the A2 phase upon cooling. Magnetization measurements showed a drop near 380 K, suggesting the Curie temperature of BCC phases, a peak at 830 K attributed to optimal magnetic alignment in the FCC phase, and a sharp decline at 950 K marking the transition to a paramagnetic state. Magnetic moment calculations provided insights into magnetic alignment dynamics, while low-temperature analysis highlighted the alloy’s magnetically soft nature, dominated by ferromagnetic contributions from the A2 phase. These findings underscore the strong interdependence of microstructural features and magnetic behavior, offering a foundation for optimizing HEAs for temperature-sensitive scientific and industrial applications. Full article

FeSiBCuNb powders, produced via the gas–water atomization method, typically exhibit a broad particle size distribution and high sphericity. Nanocrystalline soft magnetic composites derived from these powders demonstrate exceptional service stability. In this study, a series of FeSiBCuNb/FeNi nanocrystalline magnetic powder cores (NMPCs) were fabricated under varying compaction pressures and heat treatment temperatures. The effects of these parameters on the soft magnetic properties were systematically analyzed. The findings reveal that optimizing compaction pressure and heat treatment temperature significantly enhances the density of the composite powders, leading to improved magnetic permeability and reduced core loss; when compaction pressure is 1800 MPa and heat treatment temperature is 550 °C, the NMPCs display outstanding magnetic properties with a low H_c of 6.32 Oe, high μ_e of 71.9, a low P_cv of 86.3 kW/m³ at 50 mT and 100 kHz, and 351.5 kW/m³ at 20 mT and 1000 kHz. Therefore, tailoring these processing conditions can enhance the soft magnetic performance of FeSiBCuNb nanocrystalline composites. Full article

CoCrFeNi high-entropy alloys represent a novel structural material with considerable application potential in a variety of fields, including aerospace, automobiles, ships, machining, energy, soft magnetic materials, and hydrogen storage materials. The present study investigates the impact of the Al element on the structure and properties of the alloy. The preparation of the Al_xCr_1−xCoFeNi (x = 0.1, 0.2, 0.3, 0.4, 0.5) powders involved the use of a variety of elemental metal powders as raw materials and a mechanical alloying process at 350 rpm for 40 h. The sintering of the alloy powders was subsequently conducted using spark plasma sintering at 1000 °C. The microstructure of the alloys was analyzed using XRD, SEM, and EDS, and the properties were analyzed using a universal testing machine, a hardness measurement, friction and wear measurement, and an electrochemical workstation. The study shows that when x = 0.1, the crystal structure of Al_0.1Cr_0.9CoFeNi consists of a double FCC phase and a trace amount of σ phase. As the aluminum content increases, part of the FCC phase begins to transform to BCC. When x = 0.2~0.5, the alloy consists of a double FCC phase and a BCC phase and a trace amount of a sigma phase. As the BCC phase in the alloy increases, the tensile strength of the alloy increases, the ability to deform plastically decreases, and the hardness increases. The highest ultimate tensile strength of 1163.14 MPa is exhibited by Al_0.5Cr_0.5CoFeNi, while the minimum elongation is 26.98% and the maximum hardness value is 412.6 HV. In the initial stage of friction measurement, the wear mechanism of Al_xCr_1−xCoFeNi is adhesive wear. However, as the test time progresses, an oxide layer begins to form on the alloy’s surface, leading to a gradual increase in the friction coefficient. At this stage, the wear mechanism becomes a combination of both adhesive and abrasive wear. Once the oxidation process and the wear process have reached a dynamic equilibrium, the friction coefficient stabilizes, and the wear mechanism transitions to a state of abrasive wear. The Al_0.1Cr_0.9CoFeNi alloy demonstrates the lowest friction coefficient and wear rate, exhibiting values of 0.513 and 0.020 × 10⁻³ mm³/Nm, respectively, while the Al_0.5Cr_0.5CoFeNi alloy demonstrates the highest performance, with a self-corrosion voltage of 0.202 V in a 3.5 wt.% NaCl solution. The experimental findings demonstrate that, in the presence of a decline in the Cr element within a high-entropy alloy, an augmentation in the Al element can facilitate the transition of the FCC phase to the BCC phase within the alloy, thereby enhancing its mechanical properties. However, in the Al_xCr_1−xCoFeNi HEAs, the presence of the Cr-rich and Cr-poor phases invariably results in selective corrosion in a neutral NaCl solution. The corrosion resistance of this alloy is weaker than that of a single-phase solid solution alloy with a similar chemical composition that only undergoes pitting corrosion. Full article

Soft magnetic composite cores were produced by spark plasma sintering (SPS) from Ni₃Fe@ZnFe₂O₄ and NiFeMo@ZnFe₂O₄ pseudo-core-shell powders. In the Fe-Ni alloys@ZnFe₂O₄ pseudo-core-shell composite powders, the core is a large nanocrystalline Permalloy or Supermalloy particle obtained by mechanical alloying, and the shell is a pseudo continuous layer of Zn ferrite particles. The pseudo-core-shell powders have been compacted by SPS at temperatures between 500–700 °C, with a holding time of 0 min. Several techniques were used for the characterisation of the powders and sintered compacts: X-ray diffraction, scanning electron microscopy, energy dispersive X-ray spectroscopy, magnetic hysteresis measurements (DC and AC), and electrical resistivity. The electrical resistivity is stabilised at values of about 7 × 10⁻³ Ω·m for sintering temperatures between 600–700 °C and this value is three orders of magnitude higher than the electrical resistivity of sintered Fe compacts. The best relative initial permeability was obtained for the Supermalloy/ZnFe₂O₄ composite compacts sintered at 600 °C, which decreases linearly for the entire frequency range studied, from around 95 to 50. At a frequency of 2000 Hz, the power losses are smaller than 1.5 W/kg. At a frequency of 10 kHz, the power losses are larger, but they remain at a reduced level. In the case of Supermalloy/ZnFe₂O₄ composite compact SPS-ed at 700 °C, the specific power losses are even lower than 5 W/kg. The power losses’ decomposition proved that intra-particle losses are the main type of losses. Full article

Soft magnetic composites (SMCs) such as FeNi₅₀ are indispensable in modern electronics due to their high magnetic permeability and low-loss characteristics, meeting the requirements for miniaturization and high-frequency operation. However, the integration of organic materials, initially aimed at reducing the total losses, presents challenges by introducing thermal stability issues at high frequencies. To overcome this obstacle, we propose a double-layer insulating coating method, applying a complete inorganic/organic composite insulation layer to the surface of iron–nickel magnetic powder. The double-layer insulating coating insulation method aims to reduce the total losses, particularly the eddy-current losses prevalent in SMCs. Additionally, the double-layer insulating coating method helps alleviate the thermal stability issues associated with organic materials at high frequencies, ultimately enhancing the magnetic properties of SMCs. We systematically investigated the influence of different resin types on the microstructure of the double-layer insulating coating, accompanied by a comprehensive comparison of the magnetic properties of the resulting samples. The experimental findings demonstrate a significant reduction in the eddy-current losses through the double-layer insulating coating method, with the total losses decreasing by over 95% compared to the initial FeNi₅₀ magnetic powder composite (MPC) materials. Notably, the sodium silicate and silicone resins exhibited superior performances as double-layer insulating coatings, achieving total loss reductions of 1350 W/kg and 1492 W/kg, respectively. In conclusion, the double-layer insulating coating method addresses the challenges related to the total losses and thermal stability in SMCs, offering a promising approach to improve their performance in various electrical and electronic applications. Full article

When a severe plastic deformation (SPD) process is performed at high temperatures, it becomes more versatile. Designed originally for the bulk nanoconstruction of hard-to-deform alloys, high-speed high-pressure torsion (HSHPT) is an SPD method used in this research for assembling multiple layers of shape memory nanocomposites. Three hard-to-deform magnetic alloys in the cast state were used. Soft magnetic shape memory alloys, NiFeGa and FePdMn, and a potentially hard magnetic alloy, CoZr, were assembled in various composites. Both grain refinement and strong layer bonding were achieved in ZrCo/FePdMn and ZrCo/NiFeGa composites in seconds. The very short SPD time is specific to HSHPT because of the intense friction that occurs under high pressures, which generates huge amounts of heat. After SPD, the temperature rises in bulk material like a pulse, being dissipated mostly through heat conduction. The SPD parameters were carefully controlled with an advanced automation system using a programmable logic controller. Nevertheless, the major drawbacks of high-pressure torsion were overcome, and large SPD discs were obtained. Various investigation techniques (optical microscopy, scanning electron microscopy, energy dispersive spectroscopy and atomic force microscopy) show well-defined interfaces as well as a fine and ultrafine structure. Full article

High entropy alloy nanopowders were successfully prepared by liquid-phase reduction methods and their applications were preliminarily discussed. The prepared high entropy alloy nanopowders consisted of FeNi alloy spherical powders and NiFeCoCrY alloy spherical powders with a particle size of about 100 nm. The powders have soft magnetic properties, the saturation magnetization field strength were up to 5000 Qe and the saturation magnetization strength Ms was about 17.3 emu/g. The powders have the excellent property of low high-frequency loss in the frequency range of 0.3–8.5 GHz. When the thickness of the powders coating was 5 mm, the powders showed excellent absorption performance in the Ku band; and when the thickness of the powders coating was 10 mm; the powders showed good wave-absorbing performance in the X band. The powders have good moulding, and the powders have large specific surface area, so that the magnetic powder core composites could be prepared under low pressure and without coating insulators, and the magnetic powder cores showed excellent frequency-constant magnetization and magnetic field-constant magnetization characteristics. In the frequency range of 1~100 KHz; the μ_m of the magnetic powder core heat-treated at 800 °C reached 359, the μ_e was about 4.6 and the change rate of μ_e with frequency was less than 1%, meanwhile; the magnetic powder core still maintains constant μ_e value under the action of the external magnetic field from 0 to 12,000 A/m. The high entropy alloy nanopowders have a broad application prospect in soft magnetic composites. Full article

Soft magnetic Fe-Al alloys have been a subject of research in the past. However, they never saw the same reception in technical applications as the Fe-Si or Fe-Ni alloys, which is, to some extent, due to a low ductility level and difficulties in manufacturing. Additive manufacturing (AM) technology could be a way to avoid issues in conventional manufacturing and produce soft magnetic components from these alloys, as has already been shown with similarly brittle Fe-Si alloys. While AM has already been applied to certain Fe-Al alloys, no magnetic properties of AM Fe-Al alloys have been reported in the literature so far. Therefore, in this work, a Fe-12Al alloy was additively manufactured through laser powder bed fusion (L-PBF) and characterized regarding its microstructure and magnetic properties. A comparison was made with the materials produced by casting and rolling, prepared from melts with an identical chemical composition. In order to improve the magnetic properties, a heat treatment at a higher temperature (1300 °C) than typically applied for conventionally manufactured materials (850–1150 °C) is proposed for the AM material. The specially heat-treated AM material reached values (H_C: 11.3 A/m; µ_max: 13.1 × 10³) that were close to the heat-treated cast material (H_C: 12.4 A/m; µ_max: 20.3 × 10³). While the DC magnetic values of hot- and cold-rolled materials (H_C: 3.2 to 4.1 A/m; µ_max: 36.6 to 40.4 × 10³) were not met, the AM material actually showed fewer losses than the rolled material under AC conditions. One explanation for this effect can be domain refinement effects. This study shows that it is possible to additively manufacture Fe-Al alloys with good soft magnetic behavior. With optimized manufacturing and post-processing, further improvements of the magnetic properties of AM L-PBF Fe-12Al may still be possible. Full article

When the thickness of the wave-absorbing material is low, there exists the problem of the narrow wave-absorbing frequency band, making it difficult to regulate the position of the wave-absorbing peak. In this study, FeNi@SrFe-MOF composite powders were synthesized using a hydrothermal method and a liquid-phase reduction method. The composite powder was spherical, with a particle size of about 50 μm–60 μm; the core layers of the powders were porous SrFe-MOF powders with permanent magnetization, and the outer layers were FeNi alloy nano-powder coatings with a particle size of 100 nm–120 nm, which took into account both the soft magnetization and the permanent magnetization properties of the composite powders. Additionally, a directional magnetic field was applied to the powder coating. By regulating the intensity and direction of the magnetic field, the electromagnetic parameters of the composite powder coating underwent sensitive changes, allowing for the precise regulation of the electromagnetic wave absorption performance of the composite powders. With the increase in magnetic field intensity, the ε′ value decreased significantly. The ε′ values were 8.56–7.35 for H453mT and 6.73–6.12 for H472mT. When no magnetic field was applied, the Snoke limit frequency of the μ′ value was 6.0 GHz. When the magnetic field intensity increased, the Snoke limit frequency of the μ′ value increased from 6.0 GHz, without the magnetic field, to 8.3 GHz; the Snoke limit of the composite powders was shattered. After the H453mT magnetic field regulation treatment, the powder coating exhibited good impedance matching characteristics with air. When the magnetic field intensity was 453mT and the thickness of the composite powders coating was 3.5 mm, the composite powders coating showed the strongest absorption peak when the R-value was −59 dB at 7.8 GHz, and the effective absorption bandwidth reached 3.2 GHz, exhibiting superb absorbent qualities. The wave absorption property of the coating can be sensitively changed by the magnetic field regulation treatment at the condition without changing the powder structure or coating structure, which provides a new strategy for the regulation of the wave absorption property and has broad application prospects. Full article

Soft magnetic Fe₆₅Ni₂₈Mn₇ (at. %) alloy was successfully synthesized by mechanical alloying and spark plasma sintering (SPS) and, in parallel, the same composition was prepared by arc melting (AM) for comparison. Several SPS conditions were tested. X-ray diffraction and scanning electron microscopy were used to investigate the structure, phase composition, and morphology of the samples. It was found that mechanical alloying produced BCC and FCC supersaturated solid solution after 130 h of milling, with a fine microstructure (i.e., crystallite size of 10 nm). Spark plasma sintering performed at 750 °C and 1000 °C under two pressures of 50 MPa and 75 MPa revealed stable FCC phases. A single FCC phase was observed after the arc melting synthesis. The magnetic properties of milled powders and solids obtained by AM and SPS were investigated. The specimen consolidated by SPS at 1000 °C under the pressure of 50 MPa exhibits soft magnetic behavior (coercivity 0.07 Oe), whereas the mechanically alloyed sample revealed hard magnetic behavior. The specimen consolidated at 750 °C under a pressure of 75 MPa showed a higher compressive strength of 1700 MPa and a Vickers hardness of 425 ± 18 HV. As a result, sintering at 750 °C/75 MPa can be utilized to enhance the mechanical properties, while those sintered at 1000 °C/50 MPa increase magnetic softness. Full article

Additive manufacturing (AM) is an attractive set of processes that are being employed lately to process specific materials used in the fabrication of electrical machine components. This is because AM allows for the preservation or enhancement of their magnetic properties, which may be degraded or limited when manufactured using other traditional processes. Soft magnetic materials (SMMs), such as Fe–Si, Fe–Ni, Fe–Co, and soft magnetic composites (SMCs), are suitable materials for electrical machine additive manufacturing components due to their magnetic, thermal, mechanical, and electrical properties. In addition to these, it has been observed in the literature that other alloys, such as soft ferrites, are difficult to process due to their low magnetization and brittleness. However, thanks to additive manufacturing, it is possible to leverage their high electrical resistivity to make them alternative candidates for applications in electrical machine components. It is important to highlight the significant progress in the field of materials science, which has enabled the development of novel materials such as high-entropy alloys (HEAs). These alloys, due to their complex chemical composition, can exhibit soft magnetic properties. The aim of the present work is to provide a critical review of the state-of-the-art SMMs manufactured through different AM technologies. This review covers the influence of these technologies on microstructural changes, mechanical strengths, post-processing, and magnetic parameters such as saturation magnetization (M_S), coercivity (H_C), remanence (B_r), relative permeability (M_r), electrical resistivity (r), and thermal conductivity (k). Full article

In this study, we utilized MgO as an insulating buffer layer to enhance the thermal stability and soft magnetic properties of Fe-Ni soft magnetic composites (SMCs) and investigated the effect of high-temperature heat treatment on those soft magnetic properties. By employing the sol-gel process, a uniform MgO insulating layer with a thickness of 600 nm was coated onto Fe-Ni magnetic powder. Subsequently, high-density SMCs were fabricated through high-pressure compaction molding. The MgO layer remained intact up to 800 °C, leading to the FeNi@MgO@MK SMCs exhibiting enhanced permeability and reduced hysteresis loss due to grain enlargement and elimination of defects, such as dislocation stacking. Notably, the dynamic loss increase after high-temperature heat treatment was significantly regulated compared to the case of the uncoated counterpart. The results underscore the potential to improve the thermal stability and soft magnetic properties of MgO-coated Fe-Ni SMCs, rendering them suitable for various electromagnetic applications. Full article

Fe-Cr-based soft magnetic alloy (SMA) monolayer coatings with high saturation magnetization (Ms) above 1.3 T were deposited onto AISI 1010 substrate by co-axial powder feeding plasma transferred arc (PTA) welding, using FeCrBSi self-fluxing powders Fe313, which have a similar chemical composition to AISI 430 ferritic stainless steel (FSS). The effect of welding parameters on the phase assemblage, microstructure, hardness and magnetic performance of the coatings was investigated. The results show that the coating’s maximum width and the welding surplus height increased with the rise in welding heat input and powder distribution density, respectively. The coating’s Ms increased sharply, but its coercivity (Hc) decreased with the growth in the substrate dilution ratio. The coating’s Hc increased whereas its Ms decreased with the increment in welding heat input. The as-welded coating C3 with optimum magnetic performance had a dendrites–eutectics composite structure, where the columnar or equiaxed sorbitic pearlite dendritic cores surrounded by network-like eutectics α(Fe,Cr) + (Fe_1−xCr_x)₂B were the main contents. Moreover, (Fe,Cr)₇C₃ and CrB had also been detected, and they were mainly distributed in the interdendritic regions. The body-centered cubic (b.c.c.) α(Fe,Cr) multi-element solid solution contributes to a high Ms of 1.61 T, and the borides (Fe_1−xCr_x)₂B and CrB as well as (Fe,Cr)₇C₃ and other carbides cause a high Hc of 58.6 Oe and hardness HV_0.3 of 4.90 ± 0.06 GPa, much higher than that of AISI 430 FSS (HV < 1.8 GPa). The current work verifies the feasibility of fabricating Ni- and Co-free FeCrBSi SMA coatings with high Ms and high hardness via PTA welding, and since the feedstock powders have chemical composition similar to AISI 430 FSS, the work may bring about novel applications for AISI 430 FSS in particular cases where the considerable wear-resistant performance as well as superior soft magnetic and anti-corrosive properties are required. Full article

Nanocrystalline powders from the Permalloy family, Ni₇₅Fe₂₅, Ni₇₉Fe₁₆Mo₅, and Ni₇₇Fe₁₄Cu₅Mo₄, were obtained by mechanical alloying starting from elemental powders. All compositions were milled for up to 24 h in a high-energy planetary ball mill. The powders were single phase and nanocrystalline as determined by X-ray diffraction studies, with larger flatted particle sizes for Ni₇₅Fe₂₅ (about 400 μm) and Ni₇₇Fe₁₄Cu₅Mo₄ (about 470 μm), and smaller particle sizes for Ni₇₉Fe₁₆Mo₅ (about 170 μm). The homogeneity of the samples was verified by energy-dispersive X-ray spectroscopy (EDX). Soft magnetic composites were obtained by adding 3% of Araldite to the powders, followed by compaction at 700 MPa, and then polymerization. A very good powder covering by the polymer layer was proven by EDX elementals maps. The influence of composition change on the electrical resistivity of the compacts was studied. Hysteresis measurements in static and dynamic fields of up to 10 kHz were recorded, showing the influence of composition and particle size on the compact properties. Full article

Soft magnetic composite (SMC) cores have been obtained by Spark Plasma Sintering (SPS) using pseudo core–shell powders. Pseudo core–shell powders are formed by a core of soft magnetic particle (nanocrystalline permalloy or supermalloy) surrounded by a thin layer (shell) of nanosized soft ferrite (Mn_0.5Zn_0.5Fe₂O₄). Three compositions of pseudo core–shell powders were prepared, with 1, 2 and 3 wt.% of manganese–zinc mixt ferrite. The pseudo core–shell powders were compacted by SPS at temperatures between 500 and 700 °C, with a holding time ranging from 0 to 10 min. Several techniques have been used for characterization of the samples, both, powders and compacts X-ray diffraction (XRD, scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), magnetic hysteresis measurements (DC and AC) and electrical resistivity. The electrical resistivity is in the order of 1 × 10⁻² Ωm, 3–4 orders of magnitude higher than supermalloy electrical resistivity. The SPS at lower temperatures (500 °C) conserves the initial phases of the composite, but increasing the sintering temperature and/or sintering time produces a solid-state reaction between the alloy and ferrite phases, with negative consequence on the magnetic properties of the compacts. The initial relative permeability is around 40 and remains constant until to 2000 Hz. The power losses are lower than 2 W/kg until to 2000 Hz. Full article