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Compressed cores made with Fe-Si alloys are expected for smoothing and boost choke coils of switching regulators and DC-DC converters. In this study, compressed cores were made with atomized Fe-3mass%Si, and the relationships between particle size, crystal grain size and core loss were investigated. The crystal grain sizes were changed by heat treatment temperature. The following conclusions were obtained. (1) Hysteresis loss decreases with increase in crystal grain size. (2) Both contributions of classical eddy current loss assuming uniform magnetization and localized eddy current loss by domain wall movements were confirmed. It was found that anomalous eddy current loss is proportional to square root of the crystal grain size. As particle size decreases, anomalous eddy current loss becomes dominant relative to classical eddy current loss, because classical eddy current loss decreases.

Relationship between Particle Size, Crystal Grain Size and Core Loss of Fe-Si Compressed Cores