A method for manufacturing a powder magnetic core using a soft magnetic material powder, wherein the method has: a first step of mixing the soft magnetic material powder with a binder, a second step of subjecting a mixture obtained through the first step to pressure forming, and a third step of subjecting a formed body obtained through the second step to heat treatment. The soft magnetic material powder is an Fe—Cr—Al based alloy powder comprising Fe, Cr and Al. An oxide layer is formed on a surface of the soft magnetic material powder by the heat treatment. The oxide layer has a higher ratio by mass of Al to the sum of Fe, Cr and Al than an alloy phase inside the powder.

A component for an electronic device can include a metal alloy formed by a metal injection molding process. The metal alloy can have a composition of about 32 wt % to about 38 wt % cobalt and about 62 wt % to about 68 wt % iron.

A component for an electronic device can include a metal alloy formed by a metal injection molding process. The metal alloy can have a composition of about 32 wt % to about 38 wt % cobalt and about 62 wt % to about 68 wt % iron.

Provided is a new magnetic material with high magnetic stability, as well as a manufacturing method therefor, said magnetic material having a higher saturation magnetization than ferrite-based magnetic materials, and having a higher electrical resistivity than existing metal-based magnetic materials, thus solving problems such as that of eddy current loss. Ti-ferrite nanoparticles obtained through wet synthesis are reduced within hydrogen, and grains are allowed to grow while simultaneously using a phase separation phenomenon due to a disproportionation reaction to produce a magnetic material powder in which an α-(Fe, Ti) phase and a Ti-enriched phase are nano-dispersed. This powder is then sintered to produce a solid magnetic material.

Provided is a new magnetic material with high magnetic stability, as well as a manufacturing method therefor, said magnetic material having a higher saturation magnetization than ferrite-based magnetic materials, and having a higher electrical resistivity than existing metal-based magnetic materials, thus solving problems such as that of eddy current loss. Ti-ferrite nanoparticles obtained through wet synthesis are reduced within hydrogen, and grains are allowed to grow while simultaneously using a phase separation phenomenon due to a disproportionation reaction to produce a magnetic material powder in which an α-(Fe, Ti) phase and a Ti-enriched phase are nano-dispersed. This powder is then sintered to produce a solid magnetic material.

Disclosed is a method for producing a soft magnetic formed part, in which, according to the first aspect, magnetically conductive particles are melted such that electrical insulating locations are arranged locally in the interspaces interrupting eddy currents which arise when the formed part is used in a magnetic field. According to a second aspect, layers are formed from the particles in the presence of an additive, the layers are locally heated by an energy supply, or a blank is formed from the particles and the additive, the blank being heated by an energy supply. The energy supply is temporally concentrated such that the magnetically conductive particles at least surface-fuse and form a structure with interspaces, in which electrical insulating locations are formed on the basis of the additive.

A bonded soft magnet object comprising bonded soft magnetic particles of an iron-containing alloy having a soft magnet characteristic, wherein the bonded soft magnetic particles have a particle size of at least 200 nm and up to 100 microns. Also described herein is a method for producing the bonded soft magnet by indirect additive manufacturing (IAM), such as by: (i) producing a soft magnet preform by bonding soft magnetic particles with an organic binder, wherein the magnetic particles have an iron-containing alloy composition with a soft magnet characteristic, and wherein the particles of the soft magnet material have a particle size of at least 200 nm and up to 100 microns; (ii) subjecting the preform to an elevated temperature sufficient to remove the organic binder to produce a binder-free preform; and (iii) sintering the binder-free preform at a further elevated temperature to produce the bonded soft magnet.

In a method for producing an inductive component, a basic body, which includes a magnetic material, is sintered and subsequently comminuted. The comminuting has the effect of creating sintered particles, which are mixed with a binder to form at least one mixture. The at least one mixture and at least one coil are arranged in a mould and subsequently the binder is activated, so that the sintered particles form with the binder at least one magnetic core, which at least partially surrounds the at least one coil. The method allows easy and low-cost production of the inductive component with improved electromagnetic properties.

In a method for producing an inductive component, a basic body, which includes a magnetic material, is sintered and subsequently comminuted. The comminuting has the effect of creating sintered particles, which are mixed with a binder to form at least one mixture. The at least one mixture and at least one coil are arranged in a mould and subsequently the binder is activated, so that the sintered particles form with the binder at least one magnetic core, which at least partially surrounds the at least one coil. The method allows easy and low-cost production of the inductive component with improved electromagnetic properties.

A method for producing a powder magnetic core includes applying energy to a surface of a soft magnetic powder coated with an insulator, exposing the soft magnetic powder to an atmosphere having an atmospheric pressure dew point of 30 C. or higher and 15 C. or lower, and forming a molded body by pressing the soft magnetic powder at 20 MPa or more and 400 MPa or less.