Fabrication and Soft Magnetic Properties of Fe–Si–Cr Composites with Double-Insulating Layers Suitable for High-Frequency Power Applications

Soft magnetic composites (SMCs) are composed of alloy materials with the core and insulating layers as the shell. These composites exhibit high saturation magnetic sensitivity and low hysteresis loss, making them a promising material for various applications. The investigation of double layers is considered valuable as it can effectively address the issues of low resistivity and high dynamic loss that arise from non-uniform insulating layers in SMCs. In this study, Fe-Si-Cr/SiO2 particles with a core–shell heterostructure were produced via chemical vapor deposition (CVD). The Fe-Si-Cr/SiO2 materials were coated with different weight percentages (1–6%) of sodium silicate (SS). Subsequently, Fe-Si-Cr-based SMCs were synthesized through high-pressure molding and heat treatment. The effect of the SS weight percentage on microscopic changes and magnetic characteristics was investigated. These findings indicated that a concentration of 4 wt% of SS was the most effective at enhancing magnetic characteristics. The resultant SMCs exhibited high resistivity (21.07 mΩ·cm), the lowest total loss (P10 mt/300 kHz of 44.23 W/kg), a relatively high saturation magnetization (181.8 emu/g), and permeability (35.9). Furthermore, it was observed that the permeability exhibited stabilization at lower frequencies. According to these findings, the combination of CVD and double layers could lead to the further development of SMCs in a variety of applications.