Dry blending Soft Magnetic Composites
SMC components are manufactured through a powder metallurgy process during which soft magnetic powders and a binding insulator material are compressed together in order to form products with three-dimensional (3D) magnetic properties. Volatile and flammable organic solvents are currently used as a media to form insulating coatings on iron powder in complex wet processing techniques. In an effort to remove the complexity of the method and the respective cost of machinery, a new technique for production coated powders has been developed, in the context of DIELECTROMAGNETICS project. This method is based on a dry blending technology with suitable additives and can be readily accomplished using standard powder processing equipment. Through this process, powder manufacturers may produce low cost proprietary coated powders. Moreover, component producers may modify powders in house to their own specifications and tailored properties for the intended use at low cost, given the licensing of the coating technology. Producers or end users of magnetic machines and motors, particularly in the aerospace or high performance electronics sectors together with powder metallurgical companies will benefit from the implementation of the technology. This is not only because they will have an alternative to conventional commercially produced SMCs but also because they can acquire materials with the required property combinations.