| Summary: | In this work, Fe85-xSi9.6Al5.4Snx (x = 0, 0.2, 0.4, 0.6, 0.8, and 1.0) Soft magnetic powder cores (SMPCs) were prepared by Sn doping, and the effects of the doping on the microstructures and soft magnetic properties were systematically investigated. With the increase of Sn content, the dislocation density of SMPCs decreases from 0.53 × 1014 m−2 to 0.29 × 1014 m−2, so does the degree of lattice distortion and the residual stress. These changes optimize the soft magnetic properties of Fe85-xSi9.6Al5.4Snx SMPCs. Based our experiments, the effects of the crystal grain size, grain orientation, and magnetic domain motion on the magnetic properties are also discussed. At last, the best soft magnetic performance was obtained, when Sn doped with 0.8 wt.%. Fe85-xSi9.6Al5.4Snx SMPCs designed by Sn doping have excellent soft magnetic properties, which expands their application advantages in the field of power electronics, the composition design also provides an effective method for the optimization of soft magnetic properties of FeSiAl SMPCs.
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