Low-Loss Fe@BN Magnetic Powder Cores Enabled by Thiol-Functionalised Boron Nitride Interfacial Coating

Iron powder cores are widely used in cost-sensitive low- to medium-frequency applications because of their high saturation magnetisation, low cost and favourable formability. However, the low electrical resistivity of iron powders favours continuous conductive pathways between adjacent particles, leading to high-frequency eddy-current loss and heat accumulation. To combine electrical insulation, interfacial stability, magnetic-property retention and thermal diffusion in a single coating, a synergistic insulation/thermal-conduction coating based on thiol-functionalised boron nitride was designed for iron-based magnetic powder cores. Hexagonal boron nitride was surface-modified through ultrasonic activation followed by grafting with a mercaptosilane coupling agent, forming covalent linkages on the boron nitride surface. The resulting functionalised nanosheets were deposited onto water-atomised iron powders through interfacial interactions between nitrogen- and sulfur-containing functional groups and the iron surface. A coating content of 5 wt.% produced a relatively continuous and uniform interfacial layer with limited agglomeration, enabling the magnetic powder cores to combine interparticle insulation, loss reduction, magnetic-property retention and thermal transport. The optimised core exhibited a volume resistivity of 58.7 Ω·m and a total core loss of 81.2 kW/m3 at 10 mT and 100 kHz, corresponding to a 20.8% reduction relative to the pure iron core. The sample retained a saturation magnetisation of 201.4 emu/g and an effective permeability of 67.5 at 100 kHz, while achieving a thermal conductivity of 55.2 W/(m·K) and a thermal impedance of 0.215 K·m2/W. Loss-separation analysis indicates that the continuous insulating layer restricts interparticle induced-current pathways and suppresses high-frequency eddy-current loss, while the two-dimensional boron nitride framework promotes internal thermal diffusion.