Alloy Development Of Sinter-based Iron-cobalt Electrical Steel Sheets

Abstract

Iron-cobalt alloys exhibit the highest saturation polarization among industrial soft magnetic materials, enabling compact, high-flux components for aerospace and robotics. Conventionally, Fe-Co electrical steel sheets containing about 2 wt.% vanadium are produced by milling and punching. Vanadium reduces brittleness, improves machinability, and increases electrical resistivity to lower eddy-current losses, but at the expense of higher coercivity. Here, we present metal powder screen printing for near-net-shape fabrication of thin Fe-Co sheets from elementary powder mixtures combined with a master alloy. This approach enables resistivity tailoring by targeted alloying while keeping vanadium content low to further improve soft-magnetic performance. The influence of different powder types and compositions on densification, shrinkage behavior, and the resulting magnetic and electrical properties will be demonstrated, providing a route to thin Fe-Co sheets with reduced high-frequency losses and minimal post-processing.