Core-loss reduction of Fe–Si–Cr crystalline alloy according to particle size in the high frequency band

We used different sizes of gas atomized Fe–Si–Cr alloy powder to produce soft magnetic composites (SMCs), this alloy has higher resistivity than existing materials used in SMCs. These powders were prepared by sieving raw materials which had an average size from less than 25 μm to over 63 μm. Our experiments show that as particle size decreases, the magnetic saturation tends to increase, the sample made from the powder with particles 25–38 μm in size recorded the highest magnetic saturation of 169.38 emu/g. Additionally, as particle size decreased, permeability increased. The sample made from powder with particles under 25 μm had a permeability of 20.7 H/m at 1 MHz. Also, the relationship between particle size and quality factor was found to be inversely proportional. Finally, the minimum core-loss was 187.26 kW/m3 at 1 MHz for the sample made from powder whose constituent particles are under 25 μm.