Concentration-dependent construction of raspberry-like SiO2 shell on spherical FeNi towards improved electromagnetic performance from kHz to GHz

Constructing resistive layer with novel structure holds great potential in upgrading electromagnetic properties of soft magnetic materials in a wide frequency range. In this work, FeNi@SiO2 composites with controllable core–shell structures, including 2D-type laminar shell and 3D-type raspberry-like shell, were fabricated by modified Stöber method. The structure of SiO2 shell depends highly on the concentration of tetraethyl orthosilicate (TEOS). In detail, a laminar shell can be formed at low TEOS concentration, owing to slow condensation. While at high TEOS concentration, heterogeneous growth on powder surface and homogeneous growth in solution of silica networks are significantly accelerated, resulting in the formation of the raspberry-like shell. Improved electromagnetic performance of FeNi@SiO2 cores at 2 MHz, including high resistivity, low eddy current loss, and low loss factor, should be ascribed to the unique raspberry-like shell structure. Meanwhile, raspberry-like shell also contributes to enhanced attenuation and acceptable impedance matching in GHz range. Consequently, a wide effective absorption bandwidth of 8.92 GHz can be achieved at a thin thickness of 1.85 mm. This work provides deep insights into the growth mechanism of different SiO2 shells and sheds new light on the design of high-performance soft magnetic composites working in different frequency bands.