A Novel Fabrication of Spherical Fe50ni50 Alloy Powders via in-Situ De-Wetting of Liquid Solid Interface

Abstract

: Spherical Fe50Ni50 alloy powders were fabricated via a novel route based on in-situ interface de-wetting between liquid Fe-Ni alloy and alumina. The obtained Fe50Ni50 alloy particles exhibit very good spherical shape according to SEM images. Furthermore, the cross-sectional SEM images show that there are no pores and bulk inclusions in the internal region of the spherical particles. The XRD results show a trace amount of the impurity alumina phase appearing in taenite phase. The size distribution agreed well with the SEM observation confirms that the alumina powders successfully segregated pre-alloy powders. As an incidental benefit, the surface alumina particles were treated as the electrical insulation coatings. The magnetic character shows that spherical Fe50Ni50 powders exhibit a good soft magnetic property even though with a slightly decreasing of saturation magnetization due to non-magnetic coatings. Our strategies provide a method to in-situ fabricate insulation coated Fe-Ni spherical alloy powders as magnetic powder core.