Research Article
Formation of Fe-6.5wt%Si High Silicon Steel by Double Glow Plasma Surface Metallurgy Technology
Zhong Xu*
,
Jun Huang,
Hongyan Wu,
Rui Chen,
Chengyuan Zhang,
Zaifeng Xu,
Weixin Zhang,
Lei Hu,
Bin Zhang
Issue:
Volume 14, Issue 2, April 2026
Pages:
18-24
Received:
18 March 2026
Accepted:
7 April 2026
Published:
14 April 2026
DOI:
10.11648/j.ajpa.20261402.11
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Views:
Abstract: Fe-6.5wt%Si high silicon steel is recognized as an optimal magnetic material due to its low iron loss, near-zero magnetostriction, and high saturation magnetization, offering significant advantages in energy savings, weight reduction, and miniaturization of electrical equipment. However, its high brittleness presents substantial challenges for conventional manufacturing processes, and large-scale production remains a global challenge. This paper reports the successful preparation of Fe-6.5wt%Si high silicon steel using the Double Glow Plasma Surface Metallurgy Technology, also referred to as the Xu-Tec process. In this method, a dual-electrode glow discharge configuration is employed within a vacuum vessel, where silicon is sputtered from a pure source cathode and deposited onto a low-silicon steel workpiece cathode, followed by inward diffusion under argon ion bombardment at elevated temperatures. Through systematic optimization of process parameters—including source voltage, workpiece voltage, argon pressure, treatment temperature, and holding time—both homogeneous and gradient high silicon steels were successfully fabricated. Microstructural characterization and compositional analysis revealed that the homogeneous Xu-Tec high silicon steel achieved an average cross-sectional silicon content exceeding 6.5 wt%, while the gradient variant exhibited controlled silicon distribution from the surface to the core. Notably, the thickness of the Xu-Tec processed samples was twice that of the Japanese JNEX 900 and JNHF 600 products, indicating superior diffusion efficiency. The Xu-Tec process is simple, environmentally friendly, and free from corrosion and pollution, offering a promising new route for the large-scale production of high silicon steel. This study provides a foundational basis for future application research and industrialization efforts.
Abstract: Fe-6.5wt%Si high silicon steel is recognized as an optimal magnetic material due to its low iron loss, near-zero magnetostriction, and high saturation magnetization, offering significant advantages in energy savings, weight reduction, and miniaturization of electrical equipment. However, its high brittleness presents substantial challenges for conv...
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