High-strength and corrosion-resistant Fe/Al2SiO5 soft magnetic composites fabricated by a nanoscale solid-reaction coating method

• Published in: Journal of alloys and compounds Vol. 912; p. 165174
• Main Authors: Ma, Jie, Yuan, Yingbo, Zou, Haihan, Yang, Bai, Zhou, Bohui, Yu, Ronghai
• Format: Journal Article
• Language: English
• Published: Lausanne Elsevier B.V 15.08.2022; Elsevier BV
• Subjects: Aluminum oxide; Aluminum silicates; Ceramic coatings; Ceramic-reinforced composite structure; Ceramics; Cermets; Core-shell structure; Corrosion; Corrosion prevention; Corrosion resistance; Creep rupture strength; Deformation; Fe/Al2SiO5 soft magnetic composites; High comprehensive properties; High strength; High transverse rupture strength; Iron; Low temperature; Mechanical properties; Saline water; Silicon dioxide; Solid phases; Strong corrosion resistance; Thickness; High comprehensive properties; Strong corrosion resistance; High transverse rupture strength; Ceramic-reinforced composite structure; Fe/Al2SiO5 soft magnetic composites
• ISSN: 0925-8388; 1873-4669
• DOI: 10.1016/j.jallcom.2022.165174

Low mechanical performance is the key technical problem for metal-based soft magnetic composites (SMCs) with core-shell structures needed to be urgently resolved for their actual applications due to the limitation of their conventional preparation methods. In this work, dense sintered Al2SiO5 ceramic layers have been in situ formed and entirely coated on the surfaces of high-purity deformed Fe particles via a low-temperature solid-phase reaction between initially-coated amorphous nano-Al2O3 and nano-SiO2 to obtain a new ceramic-reinforced Fe/Al2SiO5 SMCs. The fully-densified Fe/Al2SiO5 SMCs exhibit a high transverse rupture strength value of 120 MPa, which exceeds those for most of present metal-based SMCs. These ceramic-coated Fe-based composites also show strong corrosion resistance in water-air and salt-water conditions due to the anti-corrosion Al2SiO5 coating layers completely isolating the deformed Fe particles from the corrosion environments. Good magnetic performance is maintained in these high-strength and corrosion-resistant Fe/Al2SiO5 SMCs due to the suitable thickness of Al2SiO5 coating layers, which promises their broad application prospects for high-power electromagnetic devices in critical environments. Moreover, the fabrication for fully-densified functional metal-ceramic composites by a nanoscale solid-state reaction coating method in this work can provide a new insight for the research and applications of the other new-type metal-based composites. [Display omitted] •New ceramic-reinforced Fe/Al2SiO5 soft magnetic composites have been fabricated.•A high TRS value of 120 MPa is obtained for Fe/AlSiO5 composites.•Fe/AlSiO5 composites show strong corrosion resistance.•Good soft magnetic properties were maintained in the composites.