Direct synthesis of Fe-Si-B-C Cu nanocrystalline alloys with superior soft magnetic properties and ductile by melt-spinning

Abstract

Structure, magnetic properties and ductile of melt-spun Fe83-xSi4B13-yCyCux (x = 0–1.7; y = 0–8) alloys were investigated. The addition of 1.7 at.% Cu in a Fe83Si4B13 amorphous alloy generates abundant α-Fe crystals by providing nucleation sites, and further C doping promotes the growth of the crystals by suitable turning amorphous-forming ability, hence they increase saturation magnetic flux density (Bs) and slightly worse magnetic softness of the as-spun alloys. The as-spun Fe81.3Si4B7C6Cu1.7 alloy possesses a combined structure of a fully amorphous layer in wheel side surface and predominating nanocrystalline structure with gradually enlarged α-Fe crystal, whose average size and volume fraction are determined as about 12 nm and 32%, respectively, therefore superior soft magnetic properties and ductile with a high Bs of 1.74 T, coercivity (Hc) of 32.7 A/m, effective permeability (μe, at 1 kHz) of 3200 and high relatively strain at fracture (εf) of 3.61% can be achieved directly in this alloy by only using melt-spinning. The annealing at 578 K releases internal stress, promotes the growth of the α-Fe crystals and remains the amorphous layer of the Fe81.3Si4B7C6Cu1.7 alloy, then improves the soft magnetic properties and maintains the superior ductile with increasing the Bs and μe to 1.80 T and 14,100, respectively, lowering the Hc to 9.4 A/m and slightly reducing the εf to 2.39%. The combination of superior soft magnetic properties and ductile and simplified synthesis process entitles the Fe-Si-B-CCu nanocrystalline alloys great potentials in high performance electromagnetic applications.