为适应高性能电子器件低能耗、高功率、小型化和高频化的发展趋势，制备综合性能优异的非晶/纳米晶软磁粉体是行业的迫切需求。本文采用水气联合雾化工艺成功制备了Fe₇₇Si_8.4B_13.6C₁和Fe₇₃Si_15.7B_7.5Cu_0.9Nb_2.9非晶粉体。对Fe₇₇Si_8.4B_13.6C₁非晶粉体进行粒度和粒度级配实验，研究了粒度和粒度级配对试样性能的影响，确定了最佳粒度配比；对Fe₇₃Si_15.7B_7.5Cu_0.9Nb_2.9非晶粉体进行热处理工艺研究，获取了最佳晶化工艺。所制备的非晶/纳米晶粉体，已实现规模化量产。

用水气联合雾化工艺制备非晶粉体，系统研究了漏眼尺寸、雾化水压力和熔体温度等工艺参数对粉体性能的影响，制备了12组Fe₇₇Si_8.4B_13.6C₁粉体。研究结果表明：漏眼尺寸从4 mm增大到6 mm，粉体平均粒径由20.53 μm增大到27.83 μm，振实密度由4.47 g/cm³增大到4.91 g/cm³，松装密度由3.61 g/cm³增大到4.23 g/cm³，流动性提升，粉体球形度逐渐提高；雾化水压力从60 MPa增大到120 MPa，粉体平均粒径由17.4 μm减小到7.8 μm，振实密度由4.54 g/cm³减小到4.23 g/cm³，松装密度由3.63 g/cm³减小到3.11 g/cm³，粉体颗粒间的团聚现象逐渐明显；熔体温度从1350 ℃增大到1650 ℃，粉体平均粒径由10.34 μm减小到5.69 μm，振实密度由4.35 g/cm³减小到3.87 g/cm³，松装密度由3.27 g/cm³减小到2.96 g/cm³，流动性较差，粉体颗粒间的团聚现象更加突出。

从12组Fe₇₇Si_8.4B_13.6C₁粉体中优选出3组工业上常用的粒度粉体，研究粒度对其性能的影响。研究结果表明：随着粉体粒度增大，振实密度由4.19 g/cm³增大到4.89 g/cm³，,松装密度由3.06 g/cm³增大到4.17 g/cm³；在100 kHz下测得的磁导率由17.6增大到20.83，在100 mT，100 kHz下测得的损耗由1600 mW/cm³增大到1954 mW/cm³；粒度对粉体的物相结构、热力学性能和饱和磁感应强度B_s等的影响较小。

对上述Fe₇₇Si_8.4B_13.6C₁非晶粉体做粒度级配研究，正交实验研究结果表明：当200目:500目:1000目=6:1:4时，性能最优：在100 kHz下测得的磁导率为24.84；在100 mT，100 kHz下测得的损耗为837 mW/cm³。

对Fe₇₃Si_15.7B_7.5Cu_0.9Nb_2.9非晶前驱体进行纳米晶化热处理，研究热处理工艺对纳米晶性能影响。研究结果表明：随着热处理温度逐渐升高，纳米晶相逐渐析出完全，一次剩余晶化焓逐渐接近于0，饱和磁感应强度B_s由142.6 emu/g增大到159.9 emu/g，矫顽力由55.7 A/m下降到48.6 A/m，在100 kHz下测得的磁导率由20.79增大到39.37，在100 kHz，B_m=100 mT下测试磁环总损耗由1550 mW/cm³下降到510 mW/cm³。在10℃/min的加热速率下，将非晶前驱体加热到560 ℃保温1 h，可获得综合软磁性能较为优异的纳米晶结构：B_s=159.9 emu/g，H_c=48.6 A/m，在100 kHz下，μe=39.37，在100 kHz，B_m=100 mT下测试磁环总损耗P_cv=510 mW/cm³。

To adapt to the development trend of low level energy consumption, superpower, miniaturization and high frequency, the preparation of amorphous/nanocrystalline soft magnetic powders with excellent comprehensive properties is an urgent demand of the industry. In this paper, the amorphous powders Fe₇₇Si_8.4B_13.6C₁ and Fe₇₃Si_15.7B_7.5Cu_0.9Nb_2.9 were successfully fabricated by the water-gas atomization. The particle size and gradation experiments of Fe₇₇Si_8.4B_13.6C₁ amorphous powder were carried out to research the effects of particle size and gradation on the performance of the sample, and the optimal particle size ratio was determined. The heat treatment of Fe₇₃Si_15.7B_7.5Cu_0.9Nb_2.9 amorphous powder was studied and the best crystallization process was obtained. The amorphous/nanocrystalline powders have been mass-produced.

12 groups of Fe₇₇Si_8.4B_13.6C₁ powders were prepared by water-gas atomization. Meanwhile, the influence of process parameters such as nozzle diameter, atomizing water pressure and melting temperature on the physical properties of the powders were studied. The results show that with the increase of the nozzle diameter from 4 mm to 6 mm, the D₅₀ of the powder increases from 20.53 μm to 27.83 μm, the tap density increases from 4.47 g/cm³ to 4.91 g/cm³, the apparent density increases from 3.61 g/cm³ to 4.23 g/cm³, and the fluidity increases, as well as the sphericity of the powder increases gradually. With the increase of atomizing water pressure from 60 MPa to 120 MPa, the D₅₀ of the powder decreases from 17.4 μm to 7.8 μm, the tap density decreases from 4.54 g/cm³ to 4.23 g/cm³, the apparent density decreases from 3.63 g/cm³ to 3.11 g/cm³, and the agglomeration phenomenon among particles is gradually obvious. With the increase of melting temperature from 1350 ℃ to 1650 ℃, the D₅₀ of the powder decreases from 10.34 μm to 5.69 μm, the tap density decreases from 4.35 g/cm³ to 3.87 g/cm³, and the apparent density decreases from 3.27 g/cm³ to 2.96 g/cm³. The fluidity is terrible, and the agglomeration between particles is more prominent.

Three groups of commonly used industrial particle size powders were selected from 12 groups of Fe₇₇Si_8.4B_13.6C₁ powders and the effects of particle size on the properties of the powders were studied. The results showed that: With the increase of particle size, the tap density increases from 4.19 g/cm³ to 4.89 g/cm³, the apparent density increases from 3.06 g/cm³ to 4.17 g/cm³, the sphericity is slightly lower, the permeability increases from 17.6 to 20.83(100 kHz), the core loss increases from 1600 mW/cm³ to 1954 mW/cm³ (100 mT, 100 kHz). The particle size has little influence on the phase structure, thermodynamic properties and saturation magnetic induction intensity B_s.

The particle size gradation of the above amorphous powder Fe₇₇Si_8.4B_13.6C₁ is researched, and the orthogonal experiment results show that: when 200 mesh:500 mesh:1000 mesh=6:1:4, the optimal performance: the permeability is 24.84(100 kHz), the core loss is 837 mW/cm³ (100 mT, 100 kHz).

The effect of heat treatment on the properties of nanocrystalline precursor Fe₇₃Si_15.7B_7.5Cu_0.9Nb_2.9 was researched. The results show that with the heat treatment temperature augments bit by bit, the nanocrystalline phase gradually precipitates completely, the primary residual crystallization enthalpy increasingly approaches 0, the saturation magnetic induction increases from 142.6 emu/g to 159.9 emu/g, the coercivity gradually reduces from 55.7 A/m to 48.6 A/m, the permeability enhances from 20.79 to 39.37(100kHz), and the core loss gradually descends from 1550 mW/cm³ to 510 mW/cm³. At the heating rate of 10 ℃/min, the amorphous precursor was heated to 560 ℃ for 1 h, the nanocrystal structure with excellent comprehensive soft magnetic properties was obtained: B_s=159.9 emu/g, H_c=48.6 A/m, μe=39.37(100 kHz), and the core loss was 510 mW/cm³ (100 mT, 100 kHz).

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