Insulation Coating of Fe–Si–Cr Soft Magnetic Powder by Selective Oxidation

This study examines the insulation coating technology of Fe–Si–Cr powder via selective oxidation annealing, which oxidizes elements selectively by controlling the oxidation potential. The study calculated the oxidation driving force of Fe, Si, and Cr, and conducted a thermodynamic analysis of oxidation and reduction conditions according to temperature and oxidation potential. Based on the results, a selective oxidation annealing was performed in an atmosphere in which Fe is reduced and only Si and Cr are selectively oxidized. The oxidation potential was controlled through the partial pressure ratio of hydrogen and water vapor. The XPS analysis results confirmed that a Si and Cr complex oxide layer formed on the powder surface after the selective oxidation annealing. Afterward, withstanding voltages were analyzed to evaluate the insulation property. Then, the withstanding voltage of the powder applying the selective oxidation annealing increased significantly compared to that of the initial powder. Further analysis showed that the powder annealed in an air atmosphere had a significantly lower saturation magnetic flux density than the initial powder, while the powder applying the selective oxidation annealing had only a slightly reduced saturation magnetic flux density.