Enhancement of electromagnetic and microwave absorbing properties of gas atomized Fe-50 wt%Ni alloy by shape modification

In order to increase the electromagnetic parameters and improve the microwave absorbing properties in the range of 1–4 GHz, gas atomized Fe-50 wt%Ni alloys with spherical form were processed in a planetary mill. The morphology, phase composition and saturation magnetization of the FeNi alloy particles were investigated by means of scanning electron microscopy, X-ray diffraction and vibrating sample magnetometer. The complex permittivity, complex permeability and reflection loss of the microwave absorbing material made from Ethylene–Propylene–Diene Monomer rubber, and the Fe-50 wt%Ni alloys were also studied using vector network analyzer and transmission line theory. The results show that the shape of the atomized Fe-50 wt%Ni powders can be modified by mechanical milling. The flaky Fe-50 wt% Ni particles were prepared, and the aspect ratio increases with increasing the milling time from 10 to 30 h. Mechanical milling does not change the phase compositions of the FeNi alloys but decreases the peak intensity and broadens the peak width. The saturation magnetization decreases and the coercivity increases as the milling time increases. The electromagnetic parameters and microwave absorbing properties are enhanced with the increase of the aspect ratio. The rubber absorbers filled with flaky Fe-50 wt%Ni powders milled for 30 h exhibit the low reflection loss in the 1–4 GHz frequency range.