Fabrication and magnetic properties of novel Fe-based amorphous powder and corresponding powder cores

In this study, Fe77P6B10Si4Nb2Cr1 amorphous powder in the particle size range below 75 µm was synthesized using industrial raw materials by water atomization. Then the amorphous magnetic powder cores (AMPCs) were prepared from the mixture of the amorphous alloy powder with different contents of epoxy resin as insulation/bonding materials by cold pressing. After annealed at 673 K for 1 h, the evolution of the high-frequency properties for the FePBSiNbCr AMPCs with the epoxy resin contents was studied. The AMPCs showed excellent magnetic properties, including high effective permeability of 62–82 with a high frequency stability up to 10 MHz, low core loss of 308–500 mW/cm3 at 100 kHz under the maximum magnetic flux density of 0.05 T, and superior DC-bias permeability of 62–72% at a bias field of 100 Oe. The development of Fe-based AMPCs with excellent soft magnetic properties is encouraging for future applications as functional materials.