本研究使用膠鑄成型法製作鐵矽鉻合金粉末一體成型電感，並比較其與乾壓成型製程製作之電感在微結構及磁性質之差異。實驗結果顯示，由於膠鑄成型法使用之低黏度漿料可大幅提升填充在微小電感線圈中柱內粉料的均勻性，順利解決乾壓成型在線圈中柱內填料不均的情形，避免中柱產生裂隙，因而具有較高的感值且直流疊加特性較佳；並由於具有較佳之粉末填充率，使得內部線圈之漆包線不會在壓製過程中被高成型壓力破壞進而產生短路的現象。但當漿料黏度過高時，雖然胚體初導磁係數提高，卻會使中柱填料不均，反而使樣品的電感值降低。此外膠鑄成型法所添加的黏結劑比例也較乾壓成型低，使初導磁係數提高。此外因黏結劑之分布較均勻，使得胚體機械強度可達乾壓成型之水準甚至更高。顯示以膠鑄成型法製作一體成型電感具有極大之潛力。

In this study, molding chokes using FeSiCr alloy powder as the raw material were prepared by gel casting, and the structures and magnetic properties of the samples prepared by dry pressing and gel casting were compared. The experimental results showed that the low-viscosity slurry used in the gel casting process can significantly improve the powder filling uniformity in the center of the coil. For the small-sized and high-inductance molding chokes, the problem of the uneven packing in the center of the coils can be effectively solved by using gel casting, thereby protecting the internal coil from being damaged and short-circuited. Therefore, the molding chokes prepared by gel-casting have higher inductance and better DC superposition characteristics than those prepared by dry pressing. However, if the viscosity of the slurry for the gel casting is too high, the packing of the center of the coil becomes worse, which leads to a lower inductance value. The proportion of the liquid binder used in the gel casting is also lower than that in molding, resulting in a higher initial permeability and the same or higher mechanical strength than that prepared by molding due to the more homogeneous distribution of the binder. It shows that molding chokes made by gel casting has a great potential.

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