在磁性金屬材料的領域當中，鐵矽合金一直以來都是廣為討論的鐵基合金，高矽量之鐵矽合金具有高電阻(80μΩ-cm)以及高相對導磁率(2.8*104)等優異之磁性質，然而為解決在高頻環境下磁性材料產生的渦流損耗，而發展出軟磁複合材料(SMC, Soft Magnetic Composite)，不同於層狀絕緣的矽鋼片，絕緣相包覆於磁性粉體，使磁性粉體彼此間互不相連，此類型材料可減少渦流損耗，具有更低的鐵損，此外，亦可以應用於三維之磁路環境，提升磁性材料設計方面的自由度。
本篇研究利用快速凝固之雙氣體霧化製程之專利製備Fe–6.5wt.%Si預合金粉末，可製備出近圓球形之粉末，搭配將此預合金粉末混合絕緣相，使絕緣相能分佈於鐵矽粉末之間，製備出具有SMC結構之粉末。
本篇研究最終將具SMC結構之混合粉末使用熱壓的方式直接成型，搭配適當時間、料溫、負載等參數，探討不同絕緣相比例之熱壓塊材其顯微組織、相分析對磁性質及機械性質的影響，其中熱壓塊材之渦流損耗最多可減少約28%，壓縮強度約為400~500MPa。

Fe-6.5wt%Si pre-alloyed powders was successfully synthesized by rapid-solidifying atomization (RSA). We mixed the Fe-6.5wt%Si powders with Bi2O3 powders by homemade v-blender. The mixed powders were synthesized into bulks by Hot Pressing (HP) with suitable parameters (pressure.temperature.time) to achieve the Soft magnetic Composites (SMCs) structure. The relationships between microstructure and properties (phase ratio, magnetic properties, and mechanical properties ) in HPed Fe-6.5Si bulk and HPed Fe-6.5Si/Ceramic SMC were investigated.

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