The role of microstructural evolution during spark plasma sintering on the soft magnetic and electronic properties of a CoFe–Al2O3 soft magnetic composite

Belcher, Calvin H.; Zheng, Baolong; MacDonald, Benjamin E.; Langlois, Eric D.; Lehman, Benjamin; Pearce, Charles; Delaney, Robert; Apelian, Diran; Lavernia, Enrique J.; Monson, Todd C.

doi:10.1007/s10853-022-06997-0

Title: The role of microstructural evolution during spark plasma sintering on the soft magnetic and electronic properties of a CoFe–Al2O3 soft magnetic composite

Journal Article · 27 February 2022 · Journal of Materials Science

DOI: https://doi.org/10.1007/s10853-022-06997-0 · OSTI ID:1846719

; Zheng, Baolong; MacDonald, Benjamin E.; Langlois, Eric D.; Lehman, Benjamin; Pearce, Charles; Delaney, Robert; Apelian, Diran; Lavernia, Enrique J.; Monson, Todd C.

Abstract For transformers and inductors to meet the world’s growing demand for electrical power, more efficient soft magnetic materials with high saturation magnetic polarization and high electrical resistivity are needed. This work aimed at the development of a soft magnetic composite synthesized via spark plasma sintering with both high saturation magnetic polarization and high electrical resistivity for efficient soft magnetic cores. CoFe powder particles coated with an insulating layer of Al ₂ O ₃ were used as feedstock material to improve the electrical resistivity while retaining high saturation magnetic polarization. By maintaining a continuous non-magnetic Al ₂ O ₃ phase throughout the material, both a high saturation magnetic polarization, above 1.5 T, and high electrical resistivity, above 100 μΩ·m, were achieved. Through microstructural characterization of samples consolidated at various temperatures, the role of microstructural evolution on the magnetic and electronic properties of the composite was elucidated. Upon consolidation at relatively high temperature, the CoFe was to found plastically deform and flow into the Al ₂ O ₃ phase at the particle boundaries and this phenomenon was attributed to low resistivity in the composite. In contrast, at lower consolidation temperatures, perforation of the Al ₂ O ₃ phase was not observed and a high electrical resistivity was achieved, while maintaining a high magnetic polarization, ideal for more efficient soft magnetic materials for transformers and inductors.

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Research Organization:: Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)

Sponsoring Organization:: National Science Foundation (NSF); USDOE Advanced Research Projects Agency - Energy (ARPA-E); USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AR0001020; NA0003525

OSTI ID:: 1846719

Report Number(s):: SAND2022-2777J; PII: 6997

Journal Information:: Journal of Materials Science, Journal Name: Journal of Materials Science Journal Issue: 9 Vol. 57; ISSN 0022-2461

Publisher:: Springer Science + Business MediaCopyright Statement

Country of Publication:: United States

Language:: English

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