Improved permeability of Fe based amorphous magnetic powder cores by adding Permalloy

This paper focuses on improving the permeability of Fe-Si-B based amorphous magnetic powder cores by addition of micron-sized ferromagnetic crystalline metal particles (Permalloy). The effects of Permalloy content, size and the amount of insulation on magnetic properties and density were investigated. The results showed that the Fe based amorphous powder cores prepared with 15 wt.% Permalloy (<15 μm particle size) have higher permeability and relatively low core loss. Furthermore, compared with Fe-Si-B based amorphous powder, the saturation magnetization of mix powder increases by 60.7%, while the magnetic powder cores coated with 3 wt.% coating agent (DC805) have low core loss of 57 W/kg at 100 kHz for Bm = 500Oe.