Correlation Between Structural Features and Magnetic Performance of Fe93.5Si6.5 (wt.%) Soft Magnetic Materials

Abstract

AbstractLaminated, powder filled, and dense bulk soft magnets are currently used for various electrical and electronic applications due to their characteristic magnetic properties. In order to systematically investigate the correlation between the structural features and the resulting magnetic performance of various soft magnetic materials, toroidal Fe93.5Si6.5 (wt.%) specimens with “layer structure”, “powder structure”, and “dense structure” are additively manufactured and characterized by means of electron beam powder bed fusion (PBF‐EB). The specimens with “layer structure” show outstanding magnetic performance in terms of low power losses and good maximum magnetic flux density at frequencies ranging from 50 to 1000 Hz, outperforming even some soft magnetic materials fabricated using conventional methods. Fe93.5Si6.5 (wt.%) specimens with various layered structures are produced using different processing strategies, allowing for sophisticated structural tailoring, and modifying the corresponding magnetic performance. Based on the results derived in this study, an ideal structure that can result in superior soft magnetic properties is proposed.