Enhancing soft magnetic characteristics of dense submicron FeNi particles with low carbon content by swirler connector assisted spray pyrolysis

Submicron spherical FeNi particles with high density and purity are required to improve the functionality of magnetic powder cores in inductors. At the current study, we present the successful synthesis of high-density (96 % dense particles) and high-purity (less than 0.3 % carbon impurity) spherical FeNi particles with a diameter of 420 nm based on a swirler-connector-assisted spray pyrolysis (SCA-SP) method. The obtained particles had saturation magnetization values higher than those of particles synthesized by conventional spray pyrolysis (CSP). A comparative study of the fluid flow and Reynolds number of the materials obtained by the SCA-SP and CSP methods was also performed using computational fluid dynamics analysis. The efficacy of SCA-SP derives from high turbulence in the flow, which enhances mass and heat transfer efficiency during gas–solid interactions in a reactor. These findings mark a considerable advance in FeNi particle synthesis, paving the way for enhanced magnetic materials with applications in various fields.