Research on the soft magnetic properties of iron–nickel magnetic powder core composite with carbonyl iron powder

In this paper, the composite soft magnetic powder core was prepared using aerosolized iron–nickel powder and carbonyl iron powder. The influence of the composite ratio of aerosolized iron–nickel powder/carbonyl iron powder on the microstructure and soft magnetic properties of the magnetic powder core samples were investigated. The results show that the carbonyl iron powder fills larger pores between iron and nickel particles, which improves the density of the core. Compared with pure aerosolized iron–nickel magnetic powder core samples, the relative permeability of magnetic powder core samples gradually increases. The magnetic powder core with 15-wt% carbonyl iron particles has the optimum comprehensive soft magnetic properties (µr=50.23, Q = 86.6 measured at 200 kHz, Pcv=185.33 kW/m3 measured at 50 mT, 100 kHz). Meanwhile, the DC bias (µH/µH=0) property was superior, which exceeds 82.1% of the effective permeability at H = 100 Oe. In addition, the cost of raw material for preparing the magnetic powder core is reduced at the same time. From an economic perspective, the present work provides new references for magnetic component researchers.