Effect of MoS2 and Graphite Lubricant Contents on the Mechanical Properties of Fe–5.0 wt.%Si Soft Magnetic Composites

This study investigated the effect of MoS2/graphite lubricant composition on the high-temperature compaction behavior, local mechanical uniformity, and microstructural characteristics of Fe–5.0 wt.%Si SMCs. Nine lubricant compositions were prepared by varying MoS2 and graphite contents, and their friction behavior, Vickers hardness, and compaction behavior were evaluated experimentally and by FEA. One-way ANOVA confirmed that lubricant composition significantly affected the Vickers hardness response (F = 4.245, p = 0.000273). The measured friction coefficients were applied as interface friction conditions in FEA, and the relative density, effective strain, and absolute hydrostatic stress distributions were compared. Among the investigated compositions, C3, containing 1.0 wt.% MoS2 and 0.3 wt.% graphite, showed the lowest friction coefficient and Vickers hardness standard deviation. In FEA, C3 also showed balanced relative density, effective strain, and hydrostatic stress distributions. XRD confirmed the α-Fe-based bcc Fe–Si matrix, while SEM-EDS indicated locally distributed lubricant-derived residual regions. Therefore, C3 was selected as the most balanced lubricant composition within the investigated range. Future studies will evaluate electromagnetic properties, including core loss and magnetic permeability.