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Al2O3 “self-coated” iron powder composites via mechanical milling
Journal article   Open access   Peer reviewed

Al2O3 “self-coated” iron powder composites via mechanical milling

Katie Jo Sunday, Kristopher A. Darling, Francis G. Hanejko, Babak Anasori, Yan-Chun Liu and Mitra L. Taheri
Journal of alloys and compounds, v 653
25 Dec 2015
DOI: https://doi.org/10.1016/j.jallcom.2015.08.260
url
http://manuscript.elsevier.com/S0925838815309579/pdf/S0925838815309579.pdfView
Published, Version of Record (VoR) Open

Abstract

Composite materials Magnetization Powder metallurgy SEM
Electrically insulated ferrous powders permit isotropic magnetic flux, lower core losses, and structural freedom for state-of-the-art electromagnetic (EM) core and device designs. Many current coating materials are limited by low melting temperatures, which leads to insufficient insulation of powders, resulting in metal-on-metal contact. Use of a high-temperature coating material, such as alumina, could alleviate these issues. In this work, iron powder was mechanically milled with alumina media, to yield plastically deformed, alumina-coated iron particles with improved magnetic saturation, elastic modulus, and hardness. Various milling times and media ball sizes are investigated to maintain particle size, insulate powders uniformly, and optimize properties after compaction and curing. We found that longer milling times yielded more dense powder coatings and lower magnetic saturation. [Display omitted] •Soft magnetic composite materials comprised of alumina coated iron powders were produced via high-energy ball milling.•“Self-coating” occurs directly from milling media, no additional powder necessary.•Low ball-to-powder ratios permit minimal particle size reduction while continuing to deform powders.•We report improved magnetic saturation for higher curing temperatures of insulated powder compacts.

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33 citations in Web of Science
34 citations in Scopus

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Collaboration types
Industry collaboration
Domestic collaboration
Web of Science research areas
Chemistry, Physical
Materials Science, Multidisciplinary
Metallurgy & Metallurgical Engineering
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