CERAMICS INTERNATIONAL
·
2025
·
IF 5.6
Chen Zhang,Benzheng Gao,Qi Li,Xin Wang,Jianliang Xie
Porosity is a characteristic feature of atmospheric plasma–sprayed (APS) coatings that strongly influences their physical and functional properties. However, studies on its effect on the electromagnetic (EM) performance and high-temperature stability of microwave-absorbing coatings (MACs) remain limited. In this work, FeSiAl/CaO–B 2 O 3 –SiO 2 composite coatings with different porosities were fabricated by adjusting powder feed rate (PFR). Microstructural evolution, EM properties, and isothermal oxidation behavior of prepared composite coatings were systematically investigated. Results show that increasing PFR reduces the extent to which particles are melted, leading to higher porosity due to the retention of unmelted particles. The increased porosity disrupted local conductive networks, altered the complex permittivity and permeability, and lowered the bonding strength of the coatings. Moreover, pores and cracks facilitated oxygen diffusion, accelerating oxidation and crack propagation at elevated temperatures. After high-temperature oxidation, the decrease in complex permittivity improved impedance matching and broadened the absorption bandwidth. These findings provide new insights into microstructure–property relationships of APS-deposited MACs and offer a strategy for tailoring the coating porosity to simultaneously optimize their EM absorption performance and high-temperature oxidation resistance.
研究领域:
材料科学
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表面工程
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功能材料
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高温防护
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电磁学
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DOI
高影响因子
ACS Applied Electronic Materials
·
2026
·
IF 4.7
Haofeng Ouyang,Zeyu Zheng,Yujun Wu,Yile Ye,Kuan Deng,Pengli Zhu,Kexin Fu,Yan-Jun Wan,Si-Yuan Liao
Abstract The rapid development of high-frequency electronic devices urgently requires electromagnetic interference (EMI) shielding materials with both high shielding effectiveness (SE) and low reflectivity. However, achieving simultaneous high shielding and low reflectivity remains a significant challenge due to the inherent impedance mismatch. Herein, an asymmetric MXene/Flaky FeSiAl (FFSA)/expandable polymer microsphere (EPM) composite foam integrating metal soft magnetic material was constructed. Due to the particularly high permeability and low loss of FFSA, it can serve as an impedance-matching layer, allowing electromagnetic waves to enter the material with minimal surface reflection. Consequently, the composite foam delivers an EMI SE of 34.6 dB and a reflection coefficient as low as 0.03, maintaining broadband shielding above 31.9 dB across 5–27 GHz. Furthermore, the foam exhibits a near-field SE of approximately –40 dB in the 1–6 GHz band and effectively blocks wireless power transmission. This study provides a feasible strategy for developing low-reflection EMI shielding materials.
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DOI
高影响因子
JOURNAL OF MATERIALS SCIENCE-MATERIALS IN ELECTRONICS
·
2022
·Vol. 33
·期 17
·13956-13967
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IF 2.779
Sun Haibo,Zhou Guohua,Guo Zhili,Wang Ce,Wang Jinghui,Zong Changbao
The high-quality TiO 2 insulating layer on the commercial gas-atomized FeSiAl powder surface was efficiently prepared within a total time of 1 h at room temperature via a one-pot sol–gel method based on a developed industry-oriented coating equipment. The core-shell structure for the chemically coated FeSiAl powders was detected by the joint tools of SEM, EDS, and FTIR. Combined with the establishment of loss separation fitting model, the regulation mechanism analysis on soft magnetic properties was carried out for the FeSiAl powder cores insulated with different TiO 2 coating amounts. It is found that the interface-pinning effect, which is closely related to the core’s density, is an important factor affecting the magnetic properties of powder cores. With the elevating TiO 2 coating amount, the hysteresis loss, the excess loss, and DC-bias property of the core specimen exhibit the same increasing tendency, while the real part of complex permeability at 100 kHz gradually decreases owing to the increase of non-magnetic gap between the particles in the core, which can impede the domain-wall motion during magnetization. Correspondingly, the eddy current loss persistently decreases and contributes only 18.7% ~ 21.6% of total core loss when the precursor concentration is over 0.08 ml/g due to the formation of the intergranular insulated structure blocking the inter-particle eddy current flows in the composites. These results offer insights into subtly regulating magnetic properties when the adjusting process parameters for the soft magnetic composites are used in high-power and high-frequency applications.
研究领域:
材料科学
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电磁学
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产品关联
DOI
高影响因子
ADVANCED POWDER TECHNOLOGY
·
2026
·Vol. 37
·期 10
·105420
·
IF 4.5
Feng Hu,Rong Wang,Xianming Ding,Liangming Gan,Xiaofan Xia,Yongji Wang,Chuan Li,Xi’an Fan,Xiaodong Wang,Zigui Luo
FeSiAl/NiO is successfully evolved into FeSiAl/(Al 2 O 3 -Ni) and further FeSiAlNi/Al 2 O 3 . • Structure evolution and performance of the fabricated SMCs were investigated. • Al 2 O 3 -Ni coating maintains high stability at sintering temperatures below 900 °C. • Sintering above 950 °C accelerates interdiffusion to form the FeSiAlNi alloy phase. • The saturation magnetization and magnetic loss were improved simultaneously. High-frequency power electronic devices require soft magnetic composites (SMCs) with low magnetic loss and high saturation magnetization. In this study, FeSiAl/(Al 2 O 3 -Ni) and FeSiAlNi/Al 2 O 3 SMCs were fabricated via sintering FeSiAl/NiO composites at various temperatures. The structural evolution and performance of the resulting SMCs were systematically investigated. At sintering temperatures of 850℃–900℃, a chemical reaction between aluminum (Al) (derived from FeSiAl) and NiO at the FeSiAl/NiO interface, yielded FeSiAl/(Al 2 O 3 -Ni) SMCs with a composite coating comprising a uniform Al 2 O 3 layer and a ferromagnetic nickel (Ni) layer. Sintering temperatures exceeding 950℃ accelerated the interdiffusion of Al from the FeSiAl core and that of Ni from the composite coating, facilitated the alloying of FeSiAl and Ni and reduced the homogeneity of the Al 2 O 3 layer, ultimately generating FeSiAlNi/Al 2 O 3 SMCs. The prepared SMCs exhibited low magnetic loss and considerably enhanced saturation magnetization, 8.5%–21.3% greater than that of the raw FeSiAl powder. This work provides a novel strategy for constructing high-quality coatings in SMCs, with the potential to advance the development of high-performance SMCs for high-frequency power electronic applications. Download: Download high-res image (225KB) Download: Download full-size image
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DOI
高影响因子
Journal of Materials Research and Technology-JMR&T
·
2025
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IF 6.6
Shoujin Zhu,Weibing Wu,Songlin Zhou,Zongyang Zhang,Shuangjiu Feng,Xian Song Liu,Xucai Kan
This study utilized FeSiAl with 200- and 600-mesh sizes as the raw material and a layered 2D semiconducting material (WS 2 ) as an insulation coating agent. FeSiAl/2.25 wt%WS 2 composites were developed through ultrasonic mixing, and the influence of the particle size on their morphology and magnetic properties was systematically investigated. Results obtained from scanning electron microscopy revealed a uniform coating of the 2D layered WS 2 on the surface of the FeSiAl particles, thus forming an efficient inorganic coating layer. Composite permeability experiments indicated that reducing the FeSiAl particle size not only enhanced the relaxation frequency( f r ) of the FeSiAl/2.25 wt%WS 2 composites but also lowered the eddy current losses, making these composites highly suitable for high-frequency operation and applications. Sample B exhibited lower magnetic loss than Sample A, with a magnetic loss equal to 367 kW/m 3 at 1 MHz and 20 mT.
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DOI
高影响因子
JOURNAL OF ALLOYS AND COMPOUNDS
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2026
·
IF 6.3
Huafeng Tian,Ben Li,Xu Wang,Xiangkun Liao,Weiping Zhou,Fei Gao,Guangsheng Luo,Zhenzhi Cheng
Rational design of both microstructure and composition to achieve magnetic-dielectric synergy serves as an effective strategy for preparing high-performance microwave absorbing materials. This study reports the successful fabrication of rod/flake-shaped FeSiAl@TiO₂ composites via a simple approach combining ball milling and tetrabutyl titanate hydrolysis. The one-dimensional (rod) and two-dimensional (flake) morphologies of FeSiAl induce magnetic shape anisotropy, effectively overcoming the Snoek’s limit and boosting both permeability and magnetic loss at high frequencies. Concurrently, the semiconducting TiO₂ coating moderates the conductive network, reducing the real part of permittivity and achieving favorable impedance matching. Furthermore, abundant heterogeneous interfaces and defects such as oxygen vacancies generated within the composite substantially enhance interfacial and dipole polarization. The synergy between these tailored magnetic and dielectric loss mechanisms results in excellent microwave absorption performance, evidenced by a minimum reflection loss (RL min ) of −50.17 dB at a matching thickness of 1.9 mm and an ultra-wide effective absorption bandwidth of 8.18 GHz at a thickness of 2.0 mm. This work presents a promising strategy for developing high-performance magnetic-dielectric absorbers.
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DOI
高影响因子
JOURNAL OF MATERIALS SCIENCE-MATERIALS IN ELECTRONICS
·
2022
·Vol. 33
·期 13
·10131-10141
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IF 2.779
Lu Hao,Dong Yaqiang,Liu Xincai,Liu Zhonghao,Ma Yan,Wu Yue,He Aina,Li Jiawei,Wang Xinmin
The phosphating treatment method has been extensively applied in the field of insulating soft magnetic powders because of its simplicity and ease of operation; however, the specific nanoscale morphology of phosphate coating layers and the interface/connection/interaction with the outer resin are still unclear. In this study, soft magnetic powder cores (SMPCs) with a nanoporous-structured phosphate coating were fabricated, in which the coating has a beneficial adsorption effect on the outer resin and can enhance the bonding force between the organic/inorganic coating. Optimized soft magnetic properties were obtained for the SMPCs with a phosphoric acid content of 0.6 wt%, including a high effective permeability of 61, low core loss of 134.6 mW/cm 3 (measured at 100 mT, 50 kHz), and high DC bias performance of 56% under a superimposed field of 100 Oe due to the favorable interactions between the insulating coating layers. These properties can be used to manufacture micro-magnetic components.
研究领域:
材料科学
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电磁学
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产品关联
DOI
高影响因子
MATERIALS & DESIGN
·
2026
·
IF 8.2
Jun Wang,Kaixuan Li,Xinyu Zhao,Hongkang Zhao,Li Liu,Rui Wang,Zhaoyang Wu
Two-step plasma-assisted ball milling enables flaking and in situ Si 3 N 4 coating of FeSiAl powders. • Strongly bonded FeSiAl/Si 3 N 4 heterointerfaces are formed with Si–N, Si–O–N, and Fe–N/Al–N bonds. • Interfacial charge redistribution induces a built-in electric field and Schottky barrier. • Magnetic-field-assisted orientation builds ordered pathways for magnetic flux and heat conduction. • FeSiAl/Si 3 N 4 composites achieve high permeability, low core loss, and enhanced thermal conductivity simultaneously. To overcome the rapid permeability degradation, high eddy-current loss, and poor thermal management of FeSiAl soft magnetic composites under high-frequency and high-power conditions, a combined strategy of two-step plasma-assisted ball milling and magnetic-field-induced orientation was developed. The first plasma-assisted milling step transformed near-spherical FeSiAl powders into high-quality flakes, while the second step constructed a dense Si 3 N 4 coating layer, forming a tightly bonded core–shell structure. Interfacial analyses revealed the formation of Si–N, Si–O–N, and Fe–N/Al–N bonds. First-principles calculations further demonstrated interfacial charge transfer from FeSiAl to Si 3 N 4 , leading to strong Al–N covalent bonding, a built-in electric field, and a Schottky barrier, which effectively suppressed interparticle charge transport and reduced high-frequency eddy-current loss. Meanwhile, magnetic-field-induced orientation promoted the ordered arrangement of flaky particles, improving magnetic-flux continuity and heat-transfer pathways. The optimized composite containing 4 wt% Si 3 N 4 achieved an effective permeability of 93.4 at 1 MHz, a total core loss of 72.2 kW/m 3 at 50 mT and 100 kHz, and a thermal conductivity of 25.9 W·m −1 ·K −1 . This work provides a new route for designing soft magnetic composites for high-frequency, high-power-density power electronic devices. Download: Download high-res image (183KB) Download: Download full-size image
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DOI
高影响因子
JOURNAL OF ELECTRONIC MATERIALS
·
2026
·
IF 2.8
Liu Xuming,Xuan Dongpo,Li Kaixuan,Wang Jun,Wang Rui,Wu Zhaoyang
FeSiAl-based soft magnetic composites (SMCs) for medium- and high-frequency electromagnetic devices require high permeability, low core loss, and efficient thermal management. However, current insulation coating strategies are limited by poor coating continuity, weak interfacial adhesion, and insufficient thermal stability. In this work, FeSiAl/Si 3 N 4 SMCs were fabricated via two-step plasma-assisted milling (PAM) combined with magnetic-field-assisted orientation forming, with the vibration frequency in the second PAM step used to regulate the microstructure, interfacial characteristics, and overall performance of the composite powders and compacts. The results show that Si 3 N 4 was successfully introduced onto the powder surface while preserving the crystal structure of the FeSiAl matrix, thereby establishing chemically bonded interfaces involving Si–N, Si–O–N, and M–N (M = Fe, Al). First-principles calculations confirm that the FeSiAl(110)/Si 3 N 4 (120) heterointerface exhibits a binding energy of −5.08 J/m 2 , with its stability originating from charge transfer and the formation of Fe–N, Al–N, and Si–N bonds. As vibration frequency increased, the continuity of the Si 3 N 4 coating layer and the interlayer insulating network first improved and then deteriorated. The 1300 rpm sample exhibited an effective permeability of 99.8 at 1 MHz, with a decline of less than 2% over 1 kHz–1 MHz, together with a saturation magnetization of 165.2 emu/g, an electrical resistivity of 192.1 Ω m, a total core loss of 72.8 kW m −3 at 50 mT/100 kHz, and a thermal conductivity of 28.3 W m −1 K −1 . These results indicate that regulating the PAM frequency provides an effective route for coordinating the magnetic, electrical, and thermal properties of FeSiAl-based SMCs.
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DOI
高影响因子
Journal of Materials Research and Technology-JMR&T
·
2026
·
IF 7.3
Feng Hu,Lan Yang,Hanya Liu,Yuqing Mu,Jindong Ge,Kaiwen Wu,Yongji Wang,Chuan Li,Xiaodong Wang,Xi'an Fan,Zigui Luo
The simultaneous improvement of core loss and saturation magnetization remains a challenge for soft magnetic composites (SMCs) used in high-frequency and high-efficiency power electronic devices. In this work, FeSiAl SMCs with Al 2 O 3 -Co composite coating were fabricated via sintering FeSiAl/Co 3 O 4 composite powders, during which interface reactions occurred between FeSiAl and Co 3 O 4 . The influence of Co 3 O 4 coating content on the microstructure and properties of the prepared FeSiAl SMCs was systematically studied. The highly intact Al 2 O 3 coating effectively enhanced the insulation between FeSiAl magnetic particles, thus reducing eddy current loss. Meanwhile, the Co coating effectively weakened the magnetic dilution effect induced by the Al 2 O 3 coating, enabling the FeSiAl SMCs to maintain a high saturation magnetization. With increasing Co 3 O 4 coating content, the thickness of the composite coating increased, leading to an elevated resistivity of FeSiAl SMCs and a continuous decrease in core loss. Furthermore, a moderate increase in Co 3 O 4 content below 7.5 wt% was conducive to improving the saturation magnetization. However, when the coating content exceeded 10.0 wt%, insufficient diffusion of Al atoms toward the reaction interface restricted the interface reaction, resulting in the formation of CoO phase in the composite coating and consequently a decline in saturation magnetization. This work provides a novel strategy for the design and preparation of high-quality inorganic coatings in SMCs.
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DOI
高影响因子
JOURNAL OF MATERIALS SCIENCE-MATERIALS IN ELECTRONICS
·
2025
·Vol. 36
·期 20
·1-13
·
IF 2.8
Xie Linqiang,Ding Jiangtao,Liu Han,Lu Di,Yu Wanchun,Hu Te,Lin Jiayang,Cheng Zhenzhi,Gao Fei,Luo Guangsheng,Zhou Weiping
Soft magnetic composites with enhanced permeability and reduced power loss are urgently needed in the next generation of power electronics and electrical machines. However, traditional insulation techniques suffer from the uneven coating or complex process, which cannot meet these requirements. Here, the feasibility of Ba(OH) 2 as a coating layer of soft magnetic powder is explored. Due to its low melting point, Ba(OH) 2 exhibits good flowability in the molten state, enabling it to evenly coat FeSiAl particles and fill interparticle gaps, thereby forming a uniform, dense insulating layer. This novel coating strategy improves the formability of the magnetic powder cores and optimizes the cores’ soft magnetic performance. Compared with SMPCs without Ba(OH) 2 coating, FeSiAl@Ba(OH) 2 SMPCs have higher magnetic permeability (μ e = 59.5), higher quality factor ( Q max = 127.3), lower high-frequency power loss ( P cv = 2062.9 mW/cm 3 @1 MHz and 50 mT), and good DC bias performance. Our results provide a new approach for the design of insulation coatings for SMPCs, demonstrating significant application potential for high-frequency electronic devices.
研究领域:
材料科学
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电气工程
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应用物理学
·
纳米技术
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产品关联
DOI
高影响因子
危险品化学品经营许可证（带存储）