Three types of gas atomization derived Fe-Si-Al magnetic powders,named as P1,P2 and P3,whose particle size distribution was determined to be in the range of 75-48,48-37.4 and＜37.4 μm,respectively,were mixed at a proper weight ratio to form a composite magnetic powder,and then the composite magnetic powder was coated by a phosphoric acid/silicone resin for realizing electrical insulation,eventuallyresulting in Fe-Si-Al composite magnetic powder cores.Effect of their weight ratio was investigated on the density and magnetic performance of the Fe-Si-Al composite magnetic powder cores.The results show that when the content of the coarse powderP1 is kept invariant,a proper increasein the content of P3 results in the increase of density,due to the gap between coarse particles in P1 being filled by fine particles in P3,and the effective permeability can be improved to a certain extent.An appropriate decrease in the Pl content,and simultaneously an increase in the P3 content can lead to the decrease of the power loss of magnetic powder cores.The obtained composite magnetic powder core with a weight ratio of the P1,P2 and P3 of 2∶5∶3 shows the lowest power loss,which was determined to be 95.5 mW/cm3 under the test conditions of 100 mT and 50 kHz.
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