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Microstructure evolution and performance regulation of SiO2-insulated FeNi soft magnetic composites during scale-up fabrication.

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Title: Microstructure evolution and performance regulation of SiO2-insulated FeNi soft magnetic composites during scale-up fabrication.
Authors: Liu, Yuting1,2 (AUTHOR), Liu, Wei1,2,3,4 (AUTHOR) weiliu@hfut.edu.cn, Huang, Ziyi1,2 (AUTHOR), Yuan, Hong1,2 (AUTHOR), Zhang, Xuebin1,2,3,4 (AUTHOR) zhxb@hfut.edu.cn, Su, Hailin1,2,3,4 (AUTHOR) hailinsu@hfut.edu.cn
Source: Journal of Materials Science: Materials in Electronics. Jun2026, Vol. 37 Issue 17, p1-14. 14p.
Abstract: With the increasing demand for high-performance soft magnetic composites (SMCs) in power electronics, scalable fabrication of SiO2-insulated FeNi SMCs remains a research hotspot while mature preparation technologies are still insufficient. This work systematically investigates the evolution of the coating process and microstructure during scale-up from 50 (gram level) to 1000 g (kilogram level). Proportionally increasing tetraethyl orthosilicate (TEOS) dosage from 1 (T-1) to 20 mL (T-20) fails to form a uniform, dense SiO2 layer, which is attributed to reduced silanol concentration caused by pH variation. Adjusting the system pH with aqueous ammonia can boost SiO2 content to a certain extent, yet the improvement remains constrained by silicon source concentration. By optimizing TEOS dosage to 40 mL (T-40), a dense, smooth, and uniform SiO2 coating is successfully obtained owing to enhanced reaction kinetics and increased silanol concentration. The T-40 powder has a silicon content of 1.7919%, close to that of T-1 (1.3716%). Correspondingly, T-40 SMCs exhibit higher core density, higher resistivity, and better anti-saturation performance, with comparable effective permeability and core loss to T-1 SMCs. Additionally, the optimized TEOS dosage endows the powder with good flowability, high thermal stability and high corrosion resistance relative to raw FeNi powder, facilitating industrial SMCs fabrication. This work provides a feasible route and novel reference for the scalable industrial production of high-performance SiO2-insulated FeNi powders. [ABSTRACT FROM AUTHOR]
Copyright of Journal of Materials Science: Materials in Electronics is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Label: Title
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  Data: Microstructure evolution and performance regulation of SiO<subscript>2</subscript>-insulated FeNi soft magnetic composites during scale-up fabrication.
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  Data: <searchLink fieldCode="AR" term="%22Liu%2C+Yuting%22">Liu, Yuting</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Liu%2C+Wei%22">Liu, Wei</searchLink><relatesTo>1,2,3,4</relatesTo> (AUTHOR)<i> weiliu@hfut.edu.cn</i><br /><searchLink fieldCode="AR" term="%22Huang%2C+Ziyi%22">Huang, Ziyi</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Yuan%2C+Hong%22">Yuan, Hong</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Zhang%2C+Xuebin%22">Zhang, Xuebin</searchLink><relatesTo>1,2,3,4</relatesTo> (AUTHOR)<i> zhxb@hfut.edu.cn</i><br /><searchLink fieldCode="AR" term="%22Su%2C+Hailin%22">Su, Hailin</searchLink><relatesTo>1,2,3,4</relatesTo> (AUTHOR)<i> hailinsu@hfut.edu.cn</i>
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  Data: <searchLink fieldCode="JN" term="%22Journal+of+Materials+Science%3A+Materials+in+Electronics%22">Journal of Materials Science: Materials in Electronics</searchLink>. Jun2026, Vol. 37 Issue 17, p1-14. 14p.
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: With the increasing demand for high-performance soft magnetic composites (SMCs) in power electronics, scalable fabrication of SiO2-insulated FeNi SMCs remains a research hotspot while mature preparation technologies are still insufficient. This work systematically investigates the evolution of the coating process and microstructure during scale-up from 50 (gram level) to 1000 g (kilogram level). Proportionally increasing tetraethyl orthosilicate (TEOS) dosage from 1 (T-1) to 20 mL (T-20) fails to form a uniform, dense SiO2 layer, which is attributed to reduced silanol concentration caused by pH variation. Adjusting the system pH with aqueous ammonia can boost SiO2 content to a certain extent, yet the improvement remains constrained by silicon source concentration. By optimizing TEOS dosage to 40 mL (T-40), a dense, smooth, and uniform SiO2 coating is successfully obtained owing to enhanced reaction kinetics and increased silanol concentration. The T-40 powder has a silicon content of 1.7919%, close to that of T-1 (1.3716%). Correspondingly, T-40 SMCs exhibit higher core density, higher resistivity, and better anti-saturation performance, with comparable effective permeability and core loss to T-1 SMCs. Additionally, the optimized TEOS dosage endows the powder with good flowability, high thermal stability and high corrosion resistance relative to raw FeNi powder, facilitating industrial SMCs fabrication. This work provides a feasible route and novel reference for the scalable industrial production of high-performance SiO2-insulated FeNi powders. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Journal of Materials Science: Materials in Electronics is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1007/s10854-026-17662-6
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              Text: Jun2026
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              Y: 2026
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