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The volume of fluid (VOF) model and the discrete phase model (DPM) were adopted for primary and secondary atomization processes, respectively. The effects of the inlet-limited delivery tube geometry on the flow field, melt breakup and particle cooling were then investigated. The results show that under the delivery tube extrusion length of 5 mm, the suction effect and the breakup efficiency can be improved, and the risk of freeze-off can be inhibited. With the decrease of the delivery tube diameter from 2.5 to 1.5 mm, the calculated median diameter is decreased by more than half and the average cooling rate is more than doubled. The industrial trial results under different delivery tube diameters match the simulation results, and the stable casting of melt with low flow rate can be realized by adopting the inlet-limited delivery tube. When the delivery tube diameter is 1.5 mm, the amorphous powder has a median diameter of 38.9 μm and optimal soft magnetic properties with saturation magnetization of 135.0 emu·g⁻¹ and coercivity of 0.26 Oe.

26:T559,

Micron-scale powdered amorphous soft magnetic materials are being aggressively pursued for miniaturized and high-efficiency power inductors working at high frequencies due to their excellent soft magnetic properties such as extremely low coercivity and high electrical resistivity originated from the disordered atomic structures and zero magnetocrystalline anisotropy. However, the limited glass forming ability of amorphous soft magnetic alloys has hindered the preparation of amorphous soft magnetic powders through gas atomization. Here, we present the development of amorphous soft magnetic alloys based on carbon containing alloys with abnormal glass forming ability, and demonstrate the preparation of fully-amorphous soft magnetic powders fabricated through the conventional medium-cooling-rate gas atomization process. Our carbon-containing Fe₇₆Si_9−xB₁₀P₅C_x alloy showed exceptional glass forming ability, characterized by a ΔT_x (T_x−T_g) value of 33 °C, and can achieve a fully amorphous state in ribbon form with a thickness of up to 68 μm. Gas atomization was performed using the alloy produced fully amorphous powder with diameter of up to 45 μm, while possessing high saturation magnetization of 167.8 emu/g (1.53 T) and coercivity of 2.3 Oe.

27:T5a1,