Precise Synthesis and Characterization of Core–Shell Metal Particles in Gas Phase

Abstract

Digital and electrical technologies are vital to achieve global sustainable development goals (SDGs). These devices and machines require high-performance powder magnetic core inductors. This study successfully enhanced the magnetic characteristics of this component by incorporating submicron-sized silica-coated FeNi (FeNi@SiO₂) particles. The Swirler-assisted spray pyrolysis method was used to achieve an efficient one-step synthesis of FeNi@SiO₂ particles. To obtain particles with high-quality coating, the effect of an additional gas flow rate (Q_a) for providing swirling flow to disperse FeNi aerosol and HMDSO vapor was investigated. The optimum Q_a resulted in FeNi@SiO₂ particles with 353 nm diameter, 25 nm shell thickness, a high coating ratio (96%), and low free SiO₂ nanoparticle impurity.