Silica-coated soft magnetic particles are essential for
some powder
magnetic cores consisting of primary (coarse particles) and secondary
(fine particles) soft magnetic particles in the advancement of electric
devices. Herein, we report the first investigation on the direct synthesis
of submicron-sized silica-coated FeNi (FeNi@SiO2) particles
as the secondary particle using a connector-assisted spray pyrolysis
route. Provided by computational fluid dynamics calculation in applying
different connector types, i.e., T-shaped and swirler, we found that
the mixing performance between FeNi and HMDSO vapor in the swirler
connector played an important role in resulting heterogeneous nucleation,
which is crucial for obtaining the higher coating ratio (CR) and fewer
undesired nanoparticles than that of the T-shaped connector. The as-prepared
submicron-sized FeNi@SiO2 particles (353 nm) with the highest
CR (95.9%) demonstrated a remarkable DC bias characteristic (I
sat) and eddy current loss values on a powder
magnetic core, promising the practical application in manufacturing
soft magnetic components.
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