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Fe-Si alloys are known for excellent soft magnetic properties and are widely used as fillers of composites for microwave applications. A change in the size and morphology of powder particles has a significant effect on the microwave properties of composites filled with such powders. In this paper, Fe75Si25 powders were produced by high-energy wet ball milling in organic media. A solution of stearic acid in petroleum ether (a surfactant solution) and acetone were used as milling media. The effect of wet ball milling conditions on the morphology and structure of the produced powders was studied by electron microscopy, X-ray diffraction, Mössbauer spectroscopy and X-ray photoelectron spectroscopy. The use of a surfactant solution and acetone as milling media promotes the plasticization of the brittle alloy Fe75Si25 and the formation of flat particles. The wet ball milling of the alloy in acetone leads to the formation of particles of a much larger thickness and smaller size in comparison to the particles produced by wet ball milling in a surfactant solution. In both cases, after milling the alloy is disordered. During the milling process the Si concentration in the alloy decreases due to the formation of surface oxide layers enriched with silicon. The frequency dependence of microwave permittivity and permeability of composites filled with produced powders was studied. The depolarization factor, percolation threshold and intrinsic permeability of produced powder particles were determined. The frequency dependence of intrinsic permeability of the particles was shown to depend strongly on the milling conditions. A change in the milling conditions makes it possible to produce Fe75Si25 powders with the required microwave properties.

Structure and microwave properties of Fe75Si25 alloys produced by high-energy wet ball milling in organic media