This paper aims to investigate different properties of the Fe-Al matrix reinforced with multi-walled carbon nanotube (MWCNT) nanocomposites with the Al volume content up to 65%, according to the Fe-Al combination. In addition, the effect of adding Co content on the improvement of the soft magnetic properties of the nanocomposites was carried out. The nanocomposites were fabricated using the powder metallurgy process. The iron-aluminum metal matrix reinforced multi-walled carbon nanotube (Fe-Al-MWCNT) nanocomposites showed a continuous increase of saturation magnetization from 90.70 A.m2/kg to 167.22 A.m2/kg and microhardness, whereas the electrical resistivity dropped as the Al content increased. The incorporation of Co nanoparticles in Fe-Al-MWCNT up to 35 vol% of Co considerably improved the soft magnetic properties of the nanocomposites by reducing the coercivity and retentivity up to 42% and 47%, respectively. The results showed that Al-based magnetic nanocomposites with a high Al volume content can be tailored using ferromagnetic particles. The composites with a volume content of magnetic particles (Fe+Co) greater than 60 vol% exhibited higher saturation magnetization, higher coercivity, and higher retentivity than the standard Sendust core. Moreover, the produced composites can be used for the lightweight magnetic core in electromagnetic devices due to their low density and good magnetic and mechanical properties.
Keywords: magnetic hybrid nanocomposites; magnetic properties; mechanical properties; nanoparticles; spark plasma sintering.