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State-of-the-art soft magnetic (SM) alloy systems such as electrical steels and permalloys exhibit large eddy current losses at high-frequency (kHz range and above), limiting their application in fast switching devices. Eddy current losses can be reduced for metallic alloys through a decrease in characteristic length scale or embedding them in an insulation layer. This work proposes the development of fine-scale core materials consisting of metallic SM nano/microparticles with magnetic, inorganic insulation layers, and their synthesis using a wet chemistry-based, scalable method for high frequency and high-power applications. More specifically, a magnetic ferrite coating (Ni0.5-xMnxZn0.5Fe2O4, x = 0.0–0.5) was applied via deposition of ferrite powder produced using a "wet chemistry-based" co-precipitation method; the ferrite was distributed through the Fe micropowder via either ball milling or ultrasonic mixing. Powder cores were prepared by compaction of the synthesized composites. Relative magnetic permeability and core loss were measured at excitation frequencies to 200 kHz. A core loss of 127 kW/m3 was measured at excitation frequency of 100 kHz and magnetization of 0.02 T. This value improves on the 199.3 kW/m3 reported in literature at identical excitation conditions for a compact formed from a composite comprising Fe microparticles coated with low-permeability Ni0.5Zn0.5Fe2O4. Ultrasonic mixing resulted in slightly lower core loss than ball milling, possibly because ball milling causes loss-increasing deformation of the Fe micropowder. XRD and SEM were used to observe composite composition and core cross-section microstructure. [ABSTRACT FROM AUTHOR]

Citric acid has been identified as an environmentally sustainable organic acid capable of leaching up to ~30% of easily accessible REEs from underclay material. An analysis of the leaching profiles was performed to discern the reaction rates, extraction efficiencies, and potential leaching mechanisms of REEs and cations of interest from ion-adsorbed underclays. The initial leaching stage follows a slow intraparticle diffusion mechanism followed by a second stage controlled by a mixed diffusion regime. The leaching profiles of Ca and P were similar to those of REEs, suggesting that REEs are most likely derived from mineral surfaces such as hydroxyapatite or crandallite rather than predominately from underclays. Fitting to a modified diffusion control model found diffusion-controlled leaching to be the primary mechanism whereas non-diffusive mechanisms made up about 22% of the extracted REEs. Gangue cations associated with underclays had less non-diffusive leaching than REE species, indicating that their leaching kinetics may be dominated by diffusion from within the material or potentially from product layer formation. Fitting to Boyd plots further indicated that REEs were leached following intraparticle diffusion control. These results have important implications for the development of more efficient and sustainable methods for extracting REEs or critical minerals from alternative feedstocks. [ABSTRACT FROM AUTHOR]