FeSiAl/SiO2 core–shell particles and Fe3Si/Al2O3 composite cores were prepared.
SiO2 surrounding FeSiAl were replaced by Al2O3 during sintering process.
Fe3Si particles were separated by Al2O3 with tunable thickness in composite cores.
Fe3Si/Al2O3 had lower core loss and better frequency stability than FeSiAl core.
The insulating layer between ferromagnetic particles can reduce core loss.