Methods of making and using annealable insulated metal-based powder particles

A method of making a core component from annealable insulated metal-based powder particles comprising:

• (a) providing annealable insulating metal based powder particles comprising
• (i) metal-based core particles, wherein the metal-based core particles have outer surfaces;
• and
• (ii) a layer of an annealable insulating material surrounding the metal-based core particles, wherein the annealable insulating material comprises at least one organic polymeric resin and at least one inorganic compound;
• and
• (iii) an inner layer of an iron-phosphorous reaction product located between the outer surfaces of the metal-based core particles and the layer of the anneable insulating material;
• (b) compacting the annealable insulated particles at a pressure of at least 20 tsi to form a core component;
• (c) heating the core component to convert the inorganic compound into a substantially continuous and nonporous insulating layer that circumferentially surrounds each of the metal-based core particles;
• and
• (d) annealing the core component at a temperature of at least 480° C.

A method of making a core component from annealable insulated metal-based powder particles comprising:

• (a) providing annealable insulating metal based power particles comprising
• (i) metal-based core particles, wherein the metal-based core particles have outer surfaces;
• and
• (ii) a layer of an annealable insulating material surrounding the metal-based core particles, wherein the annealable insulating material comprises at least one organic polymeric resin and at least one inorganic compound comprising BaO2, and B2O3;
• (b) compacting the annealable insulated particles at a pressure of at least 20 tsi to form a core component;
• (c) heating the core component to convert the inorganic compound into a substantially continuous and nonporous insulating layer that circumferentially surrounds each of the metal-based core particles;
• and
• (d) annealing the core component at a temperature of at least 480° C.

A method of preparing annealable insulated metal-based powder particles for forming compacted core components comprising:

• (a) providing an annealable insulating material in a coatable form wherein the annealable insulating material comprises at least one organic polymeric resin and at least one inorganic compound;
• (b) providing at least about 80 weight percent, based on the weight of the annealable, insulated metal-based powder particles, metal-based core particles having outer surfaces;
• (c) coating from about 0.001 percent by weight to about 15 percent by weight, based on weight of the metal-based core particles, of the annealable insulating material onto the inner layer of preinsulating material to form a layer of the annealable insulating material surrounding the metal-based core particles;
• the inorganic compound of the annealable insulating material being convertible to a substantially continuous and nonporous insulating layer that circumferentially surrounds each of the metal-based core particles upon heating after compaction;
• wherein the inorganic compound of the annealable insulating material is substantially uniformly suspended within the organic polymeric resin of the annealable insulating material.