Effects of SnO2, WO3, and ZrO2 addition on the magnetic and mechanical properties of NiCuZn ferrites

In this study, the effects of SnO2, WO3 and ZrO2 addition at levels up to 5 wt% on the magnetic and mechanical properties of Ni0.5Cu0.3Zn0.2Fe2O4 ceramics were investigated. Only Ni0.5Cu0.3Zn0.2Fe2O4 ceramic with a SnO2 addition of ≥3.5 wt% required a densification temperature of 1150 °C, while the others reached maximum densification at 1075 °C. All samples revealed a pure spinel phase and a uniform microstructure, except for the Ni0.5Cu0.3Zn0.2Fe2O4 ceramic with the WO3 addition, which showed an exaggerated grain growth accompanied with a small amount of needle-shaped Cu0.85Zn0.15WO4 second phase. The fracture mode in the pure Ni0.5Cu0.3Zn0.2Fe2O4 ceramic revealed a transgranular phase, as the CuO second phase increased the grain boundary strength; the Ni0.5Cu0.3Zn0.2Fe2O4 ceramics sintered with 5 wt% additives showed an intergranular phase. The Vickers hardness and the bending strength of the Ni0.5Cu0.3Zn0.2Fe2O4 ceramic were 733.6 and 62.0 MPa, respectively. The Vickers hardness of the ferrite with added SnO2 or ZrO2 showed only a slight improvement, while an apparent change (832.7) was observed with the addition of 5.0 wt% WO3. The bending strength of the ferrite was optimized at 75.7 MPa with 2.0 wt% SnO2 and at 90.5 MPa with 3.5 wt% ZrO2, while that of the ferrite sintered with WO3 added dropped gradually from 62.0 to 47.7 MPa as the amount of WO3 was increased from 0 to 5.0 wt% due to the non-uniform microstructure. The pure Ni0.5Cu0.3Zn0.2Fe2O4 ceramic sintered at 1075 °C had an initial permeability of 356.9 and a quality factor of 71.2. The addition of ZrO2 led to a significant increase in the initial permeability (588.4 at 5.0 wt% ZrO2), but a slight decline in the quality factor (56.6 at 5.0 wt% ZrO2).