Iron-based
Iron-based powder is a raw material of alloy powder with iron as the main component, which is widely used in the fields of mechanical parts, 3C products, porous materials, tooling materials, magnetic materials, shielding materials, surface coatings, etc., and it is the raw material of powder metallurgy with a large dosage, and it has a high cost performance ratio.
FeSiAl soft magnetic alloy powder · Iron-silicon-aluminum magnetic powder core
High resistivity · Low eddy current loss · Specifically designed for kHz–MHz high-frequency inductors and shielding applications -150 mesh ~ -500 mesh
Process Advantages
High magnetic permeability · Low magnetostriction
Both the magnetic crystalline anisotropy constant and the saturation magnetostriction coefficient are close to zero; after annealing, the material exhibits a high initial permeability and generates no noise during operation.
High resistivity · High-frequency, low loss
High resistivity effectively suppresses eddy current losses, making it suitable for kHz–MHz high-frequency applications and reducing heat generation.
Wide-temperature stability · High reliability
The magnetic properties remain stable across a wide temperature range, with a relatively high Curie temperature, meeting the demanding operating conditions of new‑energy vehicles and other applications.
High cost-performance · No precious metals
It contains no nickel, molybdenum, or other precious metals, and its cost is significantly lower than that of MPP and high-flux magnetic powder cores, offering the best performance-to-cost ratio.
Product Real-World Photos & Microscopic Morphology
SEM of gas-atomized FeSiAl powder
Spherical or near-spherical particles with uniform particle size and excellent flowability.
Real-life photos of the powder
Gray powder, packaged in vacuum‑sealed aluminum foil bags or iron drums.
Magnetic powder core/shielding sheet
High-frequency inductor cores, EMI shielding sheets, wireless charging magnetic sheets
FeSiAl soft magnetic alloy powder: a high-frequency, cost-effective magnetic powder core material.
Since its development in 1935, FeSiAl (Sendust alloy) has become the material of choice for inductor cores and electromagnetic shielding applications in the kHz–MHz frequency range, thanks to its excellent soft magnetic properties and favorable cost‑effectiveness. With a negligible magnetocrystalline anisotropy constant K₁ ≈ 0 and a nearly zero saturation magnetostriction coefficient λs ≈ 0, it exhibits high permeability, low coercivity, and low hysteresis losses. Its non‑vacuum atomized spherical powder boasts superior flowability and high tapped density, facilitating the production of high‑density magnetic cores. Typical applications include transformer cores for switching power supplies, PFC inductors, common‑mode chokes, wireless‑charging magnetic sheets, DC‑DC converter cores for new‑energy vehicles, EMI shielding sheets, and microwave‑absorbing materials. Standard particle sizes ranging from −150 mesh to −500 mesh are available, along with insulating coating services that effectively reduce high‑frequency eddy‑current losses.
Chemical Composition (wt%)
| element | Content | Impurities | ≤(wt%) |
|---|---|---|---|
| Fe | Margin (≈84–86%) | C | 0.03 |
| Yes | 8.8-9.8 | S | 0.01 |
| Al | 5.0-6.0 | P | 0.02 |
| —— Typical Impurities —— | Ni | ≤0.05 | |
| Co | Trace amounts | Cr | Trace amounts |
| Mo | Trace amounts | — | — |
* The classic Sendust alloy composition is Fe 85%, Si 9%, and Al 6%, with extremely low levels of impurities to ensure optimal magnetic properties. Refer to the batch-specific test report for precise details.
Key Magnetic Performance Parameters (Reference Values)
| Parameter | Typical value | Explanation |
|---|---|---|
| Saturation magnetic flux density Bs | High | It varies slightly depending on the composition and manufacturing process. |
| Initial permeability μi | Excellent | Typical value after annealing |
| Maximum permeability μmax | Excellent | Typical value after annealing |
| Effective permeability μe (magnetic powder core) | Wide range of options | Depending on the pressing and heat-treatment processes. |
| Coercive force Hc | Low | After annealing, the hysteresis loss is low. |
| Resistivity ρ | High | Effectively suppresses eddy current losses. |
| Curie temperature Tc | ≈400℃ | — |
| Density (dense state) | ≈7.0 g/cm³ | — |
* The magnetic properties listed above are typical reference values after sintering and full annealing; the final performance depends on the forming, insulating coating, and heat‑treatment processes.
Particle Size Specifications & Physical Properties
| Particle size specification | Corresponding mesh count | D50(μm) | Loose packing density (g/cm³) | Tap density (g/cm³) | Oxygen content (≤%) | Typical Applications |
|---|---|---|---|---|---|---|
| -150 mesh | ≤106μm | Relatively thick | ≥3.5 | — | ≤0.10 | Large magnetic cores, high-power inductors, hot-press molding |
| -200 mesh | ≤75μm | 15-18 | ≥3.2 | 4.5-4.9 | ≤0.08 | Small and medium-sized transformer cores, PFC inductors, and general-purpose powdered iron cores |
| -300 mesh | ≤48μm | 10-12 | ≥3.0 | 4.2-4.7 | ≤0.08 | High-frequency magnetic powder cores (100 kHz–1 MHz), wireless charging modules |
| -500 mesh | ≤25μm | 8-10 | ≥2.8 | 4.0-4.6 | ≤0.10 | Ultra-high-frequency (≥1 MHz) devices, shielding sheets/absorbing coatings, MIM |
* The values above are typical; refer to the factory inspection report for specific details. Insulation coating can further reduce high-frequency eddy current losses.
FeSiAl vs. Other Soft Magnetic Materials
| Material Type | Permeability | Saturated magnetic flux density | Resistivity | Cost | Typical frequency |
|---|---|---|---|---|---|
| FeSiAl(Sendust) | Middle and high | High | High | middle | kHz-MHz |
| Iron powder core | Low | High | Low | Low | <100kHz |
| MPP (iron-nickel-molybdenum) | High | middle | Very high | High | kHz-MHz |
| High Flux (High Magnetic Flux) | Middle and high | High | middle | Relatively high | <100kHz |
| Soft magnetic ferrite | Medium-low | Low | Extremely high | Low | MHz-GHz |
FeSiAl, which combines high saturation magnetic flux density, high resistivity, and low cost, is the most cost-effective soft magnetic material in the kHz–MHz frequency range.
Process Recommendations and Heat Treatment
| Craftsmanship | Recommended particle size | Key parameters | Heat Treatment Recommendations |
|---|---|---|---|
| Magnetic powder core pressing | -200 mesh / -300 mesh | Pressing pressure: 800–1400 MPa; formed after insulating coating. | Anneal at 650–750°C in N₂ or under vacuum, then cool slowly. |
| Powder metallurgy pressing + sintering | -150 mesh / -200 mesh | Press at 500–800 MPa, sinter at 1200–1300°C (in H₂ or vacuum) | Complete annealing at 1000–1150°C in an H₂ atmosphere. |
| Electromagnetic shielding film/coating | -500 mesh | Mixed with resin, calendered, or sprayed. | No annealing is required after curing. |
* For high-frequency applications, insulated‑coated products are strongly recommended to reduce eddy current losses.
Typical application areas
High-frequency inductor/transformer
Switching power supply transformers, power inductors, PFC inductors, and choke core materials
Electromagnetic shielding/absorbing
EMI shielding covers, shielding sheets, radar-absorbing coatings, magnetic shielding films
Wireless charging
Magnetic sheets for the wireless charging receiver in mobile phones and wearable devices, and magnetic cores for the transmitter.
New Energy Vehicle Electronics
DC-DC converters, OBC magnetic cores, motor-drive filters
Sensor/EMI Resistance
Magnetic sensors, current sensors, common-mode filters, and anti-interference components
Integrated molded inductor
Miniaturized power inductors and chip inductors, compatible with automated mounting.
End-to-end testing capability
Each batch of FeSiAl powder is analyzed for major elements (Fe, Si, Al), impurity levels, particle size distribution, oxygen content, and both loose‑packed and tapped densities. COA reports and magnetic property test data are provided.
Packaging & Delivery
Powder packaging
Vacuum-sealed in a double-layer aluminum foil pouch (to prevent oxidation), with an outer iron or plastic drum.
Specifications: 5 kg/bag, 20–25 kg/drum
Export packaging
Export orders are packed in wooden crates or pallets and reinforced to protect against moisture and impact.
Compatible with sea freight, air freight, and international express delivery.
Delivery time
Standard particle size in stock; ships within 3–7 days after order confirmation.
Custom particle size or insulating coating: 7–20 days
Batch Traceability
For each batch, a sample is retained, and the COA report is shipped with the goods.
Supports third-party testing (e.g., SGS)
Free sample
Free samples are provided for process validation.
Small-batch samples; bulk supply upon quality confirmation.
Customized Services
Insulation coating treatment, particle size customization, and pre-annealing treatment
Meets special operating conditions and equipment requirements
Shipping documents
COA, MSDS, ingredient list, packing list
Meets export customs clearance requirements and customer in-plant inspection standards.
Technical Support
Providing guidance on pressing and heat-treatment process parameters for magnetic powder cores.
Assist in resolving issues encountered during use.
Inquire Now for Free Samples
Fill out the form on the right or contact us directly; we will provide product samples, technical data sheets, and price quotes to help you quickly complete your additive manufacturing process validation.
Address: No.39, Liandong Yougu lnd. Park, Bachelor Street,Changsha City,Hunan Province, China.
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Address: No.39, Liandong Yougu lnd. Park, Bachelor Street,Changsha City,Hunan Province, China.
