Effects of processed parameters on the magnetic performance of a powder magnetic core

The goal of this study is to develop a high magnetic flux density and low iron loss powder magnetic core with insulated layer coating on pure iron powders of varying sizes. After processing the phosphate treatment, the insulated layer Zn3(PO4)2 was coated onto the iron powder surface. It not only maintained the magnetic flux density of pure iron, but also enhanced the electrical resistivity of the magnetic core by reducing eddy current loss, which allowed a wider frequency range. In addition, the annealing treatment after the compression process raised the magnetic flux density of the magnetic core; however, an annealing temperature above 200 °C caused the binder to decompose, resulting in decreased electrical resistivity. Experimental results indicate that the best magnetic performances were achieved with a powder magnetic core of fine and coarse iron powder proportion of 2:1, phosphate treatment of 90 s, and an annealing temperature of 200 °C.