The influence of fine powder content on the properties of FeNi50 soft magnetic composites

The development of novel soft magnetic composites (SMCs) is driven by the demand for lightweight and highly stable electronic components. In this work, the influence of fine powder content on the properties of high-flux SMCs was systematically investigated by the particle size distribution of FeNi50 powders across a broad range from 0 to 100 wt%. Furthermore, the differences between the two powders were compared, and the effects on the properties of the SMCs were analyzed. The density of SMCs reached a maximum at a fine powder content of 20 wt% and increased gradually as the fine powder content exceeded 40 wt%. The effective permeability of SMCs was found to be strongly dependent on density and changed accordingly. The quality factor of SMCs increased gradually as the fine powder content rose, indicating a progressive enhancement of high-frequency magnetic performance. The decrease in power loss with the increase in fine powder content can be attributed to the lower hysteresis loss and intraparticle eddy current loss. The DC-bias performance gradually increased as the fine powder content increased. These parameters varied with the fine powder content, showing that reducing the average powder particle size could improve the high-frequency magnetic performance of SMCs. The current work introduces a convenient approach to producing high-performance SMCs that can meet the requirements of electronic components in the future.