High-performance FeSiAl SMCs for MHz applications enabled by insulating coatings of bioinspired NiZn ferrite nanoparticles

doi:10.1016/j.jmst.2025.08.072

J. Mater. Sci. Technol. ›› 2026, Vol. 260: 30-39.DOI: 10.1016/j.jmst.2025.08.072

• Research Article • Previous Articles Next Articles

High-performance FeSiAl SMCs for MHz applications enabled by insulating coatings of bioinspired NiZn ferrite nanoparticles

Yu Jiacheng^a,1, Li Zhaocheng^b,c,1, Zhang Wenmiao^d, Zhang Tongwei^a,f,*, Che Renchao^e,*, Zhang Yuele^a,f, Fang Fengjiao^a,f, Cao Changqian^a,f,*, Pan Yongxin^a,f

^aKey Laboratory of Planetary Science and Frontier Technology, Institute of Geology and Geophysics, Chinese Academy of Sciences, Beijing 100029, China;
^bNBTM NEW MATERIALS GROUP CO., LTD., Ningbo 315000, China;
^cThe State Key Laboratory of Powder Metallurgy, Central South University, Changsha 410000, China;
^dCollege of Rare Earths, Jiangxi University of Science and Technology, Ganzhou 341000, China;
^eLaboratory of Advanced Materials, Shanghai Key Lab of Molecular Catalysis and Innovative Materials, Sate Key Laboratory of Coatings for Advanced Equipment, College of Smart Materials and Future Energy, Fudan University, Shanghai 200438, China;
^fCollege of Earth and Planetary Sciences, University of Chinese Academy of Sciences, Beijing 100049, China

Received:2025-05-19 Revised:2025-08-13 Accepted:2025-08-14 Published:2026-07-20 Online:2025-10-15
Contact: *E-mail addresses: ztw@mail.iggcas.ac.cn (T. Zhang), rcche@fudan.edu.cn (R. Che), changqiancao@mail.iggcas.ac.cn (C. Cao)
About author:1 These authors contributed equally to this work.

Abstract

Abstract: The exponential growth of artificial intelligence (AI) computational power has imposed more stringent demands on developing high-performance electronic components capable of operating efficiently at high frequencies. However, achieving high-frequency operation, enhanced power capacity, and miniaturization simultaneously in soft magnetic composites (SMCs) remains a formidable challenge. Traditional insulation coating approaches to improving the high-frequency performance of SMCs have been limited by difficulties in controlling coating thickness, susceptibility to decomposition during heat treatment, and magnetic dilution effects caused by non-magnetic insulating materials. This study addresses these limitations by introducing a novel biomineralization-inspired strategy to coat FeSiAl powders with NiZn ferrite nanoparticles. Inspired by the biomineralization in natural protein nanocages, we synthesized NiZn ferrite nanoparticles with uniform size distribution, exceptional monodispersity, and superparamagnetism through a confined mineralization strategy. The resulting NiZn ferrite/FeSiAl composites, prepared via mechanical mixing, exhibited an heterogenous insulation coating that significantly enhanced magnetic domain wall mobility and electrical resistivity compared to uncoated FeSiAl SMCs. Consequently, the FeSiAl/NiZn (FSA-NZ) SMCs demonstrated enhanced relative permeability, a high domain-wall resonance frequency, and remarkably low high-frequency power loss (944.8 mW/cm³ at 1 MHz/50 mT). This study bridges the gap between bioinspired materials engineering and high-frequency soft magnetic materials and provides a viable solution to the long-standing challenges in developing high-performance SMCs for MHz applications.

Key words: Soft magnetic composites, Biomimetic synthesis, Loss separation, NiZn ferrite, Insulation technology

Yu Jiacheng, Li Zhaocheng, Zhang Wenmiao, Zhang Tongwei, Che Renchao, Zhang Yuele, Fang Fengjiao, Cao Changqian, Pan Yongxin. High-performance FeSiAl SMCs for MHz applications enabled by insulating coatings of bioinspired NiZn ferrite nanoparticles[J]. J. Mater. Sci. Technol., 2026, 260: 30-39.

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High-performance FeSiAl SMCs for MHz applications enabled by insulating coatings of bioinspired NiZn ferrite nanoparticles

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