High-performance FeSiAl soft magnetic composites achieved by confined solid-state reaction

Soft magnetic composites (SMCs) consisting of insulated metallic magnetic particles are critical materials in modern electronics. However, the simultaneous optimization of power loss and permeability for SMCs remains challenging due to the vulnerable insulation layer inside. Here, we succeed in fabricating FeSiAl SMC by confined solid-state reaction between TiO ₂ and FeSiAl matrix, which leads to the formation of homogeneous and lattice-matched Al ₂O ₃ layer and brings about effective electrical insulation of FeSiAl particles. TiO ₂ can progressively release O atoms and confine the solid-state reaction strictly within the interfacial region. Meanwhile, itself becomes ferromagnetic with deficient oxygen, resulting in alleviated magnetic dilution. Fast domain wall displacement and small hysteresis loss are directly observed by in-situ Lorenz transmission electron microscopy. The obtained FeSiAl SMC exhibits low power loss of 130 mW·cm ⁻³ (50 mT, 100 kHz) and high effective permeability of 143, which is desired in energy-saving and high-efficiency devices. This work relates the interfacial behavior with magnetic properties and highlights a new strategy for fabricating high-performance SMCs.