Low Hysteresis Loss Research Articles

Morphotropic phase boundary evolution with synergistic effect of sintering temperature to improve electrocaloric and energy storage performances of lead-free Ba0.95Ca0.05Sn0.09Ti0.91O3 (BCST) ceramic

The designing of lead-free ferroelectric ceramics for application in environment-friendly efficient electrocaloric cooling and energy storage devices is still challenging and need to be considered. A major challenge, however, is how to simultaneously achieve higher polarization and low hysteresis loss at low applied electric field. In this perspective, we comprehensively investigated sol-gel derived Ba0.95Ca0.05Sn0.09Ti0.91O3 (BCST) ceramics by varying the sintering temperature to explore its electrocaloric and energy storage capabilities. The excellent ∆T ∼ 1.03 K, ∆S ∼ 1.32 J/kg.K and high electrocaloric responsivity ΔT/ΔE ∼ 0.34 K.mm/kV at very low applied electric field of 30 kV/cm are obtained for pristine BCST sample sintered at 1400 °C. Additionally, we observed Wrec ∼ 136.18 mJ/cm3 and giant energy conversion efficiency η ∼ 94.29 % under very low applied electric field of 30 kV/cm for the same BCST sample. Our results reveal that control of sintering temperature contributes to a favorable and stable microstructure, including R-O-T phase coexistence and substitutional heterogeneity-induced nano-polar regions (PNRs) which strengthens the Polarization and supports the thin hysteresis loop. Thus all these factors simultaneously contributing to make BCST ceramic as a potential material for applications in advanced electrocaloric cooling and energy storage capacitors.

Interdiffusion mechanism of hybrid interfacial layers for enhanced electrical resistivity and ultralow loss in Fe-based nanocrystalline soft magnetic composites

Soft magnetic composites (SMCs) composed of ferromagnetic particles and insulating binder are highly desired in energy-saving and high-efficiency devices for their high electrical resistivity and softer saturation characteristics. However, traditional insulation coatings are facing thermal instability, inhomogeneous distribution, and magnetic dilution, presenting a major challenge for the trade-off relationship between power loss and permeability. Here, the phosphate-coated FeSiBCuNb/SiO2 SMC is successfully fabricated by a unique interdiffusion effect in hybrid interfacial layers, which shows a combination of ultralow power loss of 135.8 kW/m3 (50 kHz/100 mT), high effective permeability of 80.6, and good temperature stability. The interdiffusion behavior between Si/O and Fe/P/O elements promotes the formation of ultrathin, uniform, and multilayer interface structure, which alleviates the magnetic dilution. Penetrating oxidation at the edge interface and elements interdiffusion effect contribute to a higher electrical resistivity induced by hot isostatic pressing with rapid quenching, leading to a low eddy current loss. Synergistic effect of isostatic pressures and rapid quenching facilitates the formation of high-density Cu clusters corresponding to ultrafine microstructure, which is beneficial for low coercivity and low hysteresis loss. This study involves the interdiffusion mechanism of hybrid interfacial layers and nanocrystalline behavior, providing a new strategy for the next-generation of high-performance SMCs.

Ultrahigh-temperature capacitors realized by controlling polarization behavior in relaxor ferroelectric

Dielectric film capacitors have drawn much attention in recent years due to the fast charge–discharge rate, while the energy storage performance at ultra-high temperature needs to be satisfied for the increasing demand of the market. Here, we develop an ultrahigh-temperature capacitor of relaxor ferroelectric (RFE) films via controlling polarization behavior. The (110) oriented 0.85BaTiO3-0.15Bi(Mg0.5Zr0.5)O3 (BT-BMZ) thin film, with anisotropic strain and the optimal ratio of extrinsic/intrinsic polarization, exhibits minimized hysteresis loss and maintains maximum polarization. The (110) oriented film capacitor shows giant energy storage density 104.94 J/cm3, with energy storage efficiency 75.83 % BT-BMZ at room temperature. Moreover, the BT-BMZ capacitor achieves excellent thermal stability, from −100 °C to 400 °C, with an energy density 51.61 J/cm3 at an efficiency 79.36 % due to the low leakage current and hysteresis loss. This work demonstrates that the energy storage performance can be enhanced by adjusting the ratio of intrinsic/extrinsic polarization and provides a feasible method for improving high-temperature performance of capacitors.

Stretchable rubber composites with lower hysteresis losses, improved magnetic effect, and a robust magnetic sensitivity

The stretchable materials exhibit various challenges such as high hysteresis losses, lower magnetic effect, and less magnetic sensitivity. In this work, we design and fabricate stretchable magnetic-rheological elastomers based on silicone rubber with robust magnetic sensitivity and lower hysteresis losses. The nanofillers used were carbon black (CB), and electrolyte iron particle (EIP). The stretchable materials obtained show an anisotropic effect of up to 165%. Moreover, the hysteresis losses were 0.4 kJ (control), 2.45 kJ (15 phr of CB), 0.58 kJ (60 phr of EIP), and 3.53 kJ (60 phr of hybrid filler system). The compressive modulus was 1.4 MPa (control), 3.76 MPa (15 phr of CB), 2.1 MPa (60 phr of EIP), and 3.9 MPa (60 phr of hybrid filler system). The fracture strain was 164% (control), 160% (15 phr of CB), 100% (60 phr of EIP), and 139% (60 phr of hybrid filler system). To sum up, the CB shows robust mechanical properties with high stretchability. However, the hybrid filler system shows high stiffness with a higher magnetic response. Finally, EIP-filled composites show optimum stiffness and robust magnetic response force.

Co-hydrolysis of TEOS and DDS to obtain a modified hydrophobic SiO2 insulation layer for FeSiBC amorphous magnetic powder core with low energy loss

The hysteresis effect and eddy currents caused by alternating magnetic fields greatly impede the improvement of the working efficiency and performance stability of soft magnetic powder cores. In this work, modified hydrophobic SiO2 nanoparticles were prepared by tetraethyl orthosilicate (TEOS) and dimethyl-diethoxy-silane (DDS) as co-precursors through sol–gel methods. The effect of different proportions of DDS and TEOS on the amorphous magnetic powder cores performance was studied. It was demonstrated that the insulation layer in DDS and TEOS co-precursors hydrolyzed composite powders exhibited more uniform distribution compared with TEOS hydrolyzed alone counterpart. The introduction of methyl groups reduced the accumulation of hydrolysis intermediates on the surface of FeSiBC powders. Furthermore, the addition of DDS reduced eddy current loss significantly with a low hysteresis loss. The total energy loss of the DDS and TEOS co-hydrolysis powder core were reduced by 16.1 % and 7.7 % at 1 MHz, 0.05 T compared to the uncoated powder core and the TEOS hydrolysis alone counterpart, respectively. The presented results provide insights into improving the application range and energy utilization efficiency for the magnetic powder cores.

Ultralow-loss soft magnetic composites with temperature-resistant and insulated Al2O3/SiO2 layers through pyrolysis

Soft magnetic composites (SMCs) with low power loss are urgently needed to meet the increasing demand for high frequency and miniaturized inductors and transformers. Ultrathin cladding with good insulation and high temperature resistance is the key to achieve low-loss SMCs. In this study, we used MQ silicon resin as precursor to produce in-situ grown Al2O3/SiO2 composite insulating layer in FeSiAl SMCs through pyrolysis process and high-temperature reaction. The morphologies, microstructures and compositions of the coatings on the surface were characterized by SEM, TEM, EDS, TG, XRD, FTIR and XPS, and the results show FeSiAl powders are evenly and entirely covered with an inner Al2O3 and outer SiO2 composite insulating layer. The results of powder resistivity show that the insulating layer still maintains very high resistance after annealing at 750 °C. The composite insulating layer had high resistivity and reduced eddy current loss, while the high temperature annealing process reduced stress and defects and resulted in low hysteresis loss. The best magnetic properties were obtained from samples coated with 2.0 wt% MQ and annealed at 750 °C, with an effective permeability of 76 and the lowest power loss of 72.2 mW/cm3 at 50 mT/100 kHz, 88.5 mW/cm3 at 100 mT/50 kHz and 304.1 mW/cm3 at 100 mT/100 kHz.

Extremely low coercivity of powder Co-rich amorphous alloy obtained by gas atomisation

A novel Co-base soft magnetic powder with ultra-low coercivity was produced by inert gas atomisation. The as-atomised powder is fully amorphous owing to its high glass forming ability and the proper selection of atomisation conditions; it exhibits a very low coercivity (0.130 Oe) mainly due to the low magnetostriction coefficient of Co-based alloys. After production, the powder was annealed at different temperatures between 300 and 600 ºC for 30 minutes. Crystallisation started at around 575 ºC, which is the temperature of the first exothermic peak detected by differential scanning calorimetry. Annealing the powder at temperatures below 550 ºC develops only structural relaxation of the amorphous structure. The smallest coercivity (0.056 Oe) was found in the sample annealed at 400 ºC. On the other hand, an increment of the coercivity of four orders of magnitude occurred after full crystallisation at 600 ºC (394.320 Oe). From the analysis of the curves of anisotropy field distribution, it can be concluded that this Co-base alloy shows lower average anisotropy field, a more gaussian shape and a wider distribution than Fe-base alloys. This is explained by a lower magnetoelastic anisotropy and a more homogeneous distribution of the magnetic anisotropy. The powder exhibits a spherical shape that makes it very suitable as ferromagnetic phase to manufacture powder cores with extremely low hysteresis loss for medium-high frequency applications.

Improved energy storage performance achieved in (Bi0.5Na0.5)TiO3-based relaxor ferroelectrics via composition engineering

The utilization of relaxor-ferroelectrics is considered to become a feasible scheme to achieve high energy storage performance owing to their high polarization and low hysteresis loss. Herein, the (1-x)(Bi0.5Na0.5)TiO3-x(Sr0.7La0.2)(Ti0.9Zr0.1)O3 ((1-x)BNT-xSLTZ) ceramics were synthesized by using the traditional solid-state reaction method. A favorable recoverable energy density (Wrec) of 4.0 J cm−3 could be obtained at 295 kV cm−1 by combining composition-driven intensive relaxation behaviors and fine grains. Further, the high stabilities for temperature and frequency, with energy density of 1.56–1.41 J cm−3 over a range of 25–150 °C at 150 kV cm−1 and energy density of 1.48–1.67 J cm−3 at 150 kV cm−1 ranging from 1 Hz to 200 Hz, are achieved in 0.6BNT-0.4SLTZ. These results suggest that the BNT-SLTZ relaxor ferroelectric ceramics have capacity of becoming a promising candidate for high-power energy storage applications.

Stepwise Tailoring of Perovskite Nucleation Dynamics and Defect Formation Using a Supersaturation‐Suppression Layer for Developing Efficient and Stable Perovskite Solar Cells

Tailoring crystal growth and defects in perovskites, a viable strategy for suppressing non‐radiative recombination, is widely employed for developing efficient and stable perovskite solar cells (PSCs). However, simultaneous tailoring of crystal growth and defects in PSCs is challenging owing to several limitations; for example, excessive interactions between additives and perovskite precursors impede crystallization, and additive‐induced impurity phases can substantially increase the defect density in perovskite films. In this study, we introduced a metal‐induced supersaturation‐suppression layer (SSL) as a pseudo‐additive interfacial layer to tailor the crystallization dynamics and defect formation in perovskite crystals in steps. The proposed perovskite modification process involves an SSL‐induced metal–halide ion reaction, which modulates the crystallization kinetics for grain growth and enables the formation of metal–halide complex anion adducts that can reduce crystalline defects and suppress non‐radiative recombination while facilitating preferential perovskite crystal growth by alleviating residual strains. Because of these stepwise synergistic effects, the SSL‐based PSCs exhibited significantly improved device performances (23.4%), low hysteresis losses, and enhanced atmospheric operational stability.

Hysteresis Stress, Strain and Penetration Analysis of Spur Gear Assembly for Various Sustainable Design

This paper considers and compares the hysteresis stress and strain and the penetration property of spur gear assemblies based on three unique designs. Spur gear plays an important part in mechanical structures, and any mechanical setup should consider the execution of such a mechanical component under distinct designs to improve its mechanical productivity and sustainability. To explore the ways in which the mechanical behaviour of the designs varies with the design configurations, we integrate simulation analysis with an experimental study. The outcomes of this paper indicate considerable differences in both hysteresis stress, strain distribution, and penetration behavior measurements between three designs. The paper explains the stated disparities by the unique geometric layouts and material characteristics of each design. Furthermore, it emphasizes that some of the examined designs have lower hysteresis losses and favourable stress and strain distributions, which positively affects the long-term performance of gear systems. Other designs, however, exhibit severe penetration and stress concentrations leading to rapid gear wear and likely premature failure. In distinguishing these events, the present study offers a valuable approach to the parameters that influence the performance of gear systems and aids in the improvement of the design methodology.

Controlling electromagnetic and mechanical behaviors of geopolymer matrix with nano-SiO2@Fe3O4 magnetofluid for soft magnetic applications

Nano-SiO2@Fe3O4 magnetofluid modified geopolymer (NMMG) is presenting promising application potential in the field of magnetic building materials by virtue of its high magnetic permeability. This work aims to reveal the modification mechanisms of nano-SiO2@Fe3O4 magnetofluid on the electromagnetic and mechanical behaviors of geopolymer matrix, thus providing theoretical guidance for the engineering applications of NMMG. The results show that the introduction of nano-SiO2@Fe3O4 magnetofluid enhances the magnetic exchange energy between adjacent magnetic moments inside the geopolymer, thus weakening the coercivity by intensifying the rotation of magnetic domains inside the geopolymer, which provides a new idea for the application of NMMG in the field of soft magnetic construction materials. In addition, when the concentration of nano-SiO2@Fe3O4 magnetofluid reaches 9.4 vol%, good balance is found in the electromagnetic and mechanical behaviors of NMMG material. In that regard, NMMG can achieve satisfactory mechanical performance, ensuring as well low eddy current and hysteresis losses under alternating magnetic field, which reflects its great potential in soft magnetic applications.

Magnetocaloric effect in large temperature window on off-stoichiometric Ni-Mn-Ga-based Heusler alloys

Nickel-Manganese-Gallium-based Heusler alloys have been extensively studied for magnetic cooling applications with different compositions. However, the large hysteresis and narrow range of working temperatures associated with the first-order phase transition make limit their practical application. In this direction, the magnetocaloric effect was analyzed for three different off-stoichiometric compositions of Ni50+y+zMn25+x-yGa25‐x‐z alloys, where x, y, and z vary once at a time. Ni50Mn27Ga23 (NMG 1) and Ni54Mn21Ga25 (NMG 2) samples show large magnetocaloric effects across the second-order ferromagnetic to paramagnetic phase transition. Another sample Ni54Mn25Ga21 (NMG 3) undergoes coupled magneto-structural transition near room temperature with very low hysteresis loss (⁓4 J/kg) and a very high sensitivity of the martensite transition temperature (⁓3.6 K/T) with the field. By cyclic cooling protocol reliable magnetic entropy changes are found to be maxima of − 1.98 ± 0.09, − 1.90 ± 0.11 and − 3.53 ± 0.14 J/kg-K for 3 T field change with large effective RCP values of 235.8 ± 0.1, 161.5 ± 0.1 and 144.7 ± 0.3 J/kg for NMG 1, NMG 2 and NMG 3, respectively. The presence of inter-martensite transition along with the magnetic transition or magneto-structural phase transition widens the range of working temperature which effectively enhances the magnetic cooling performance of these materials. The TC and TM are tuned in Ni-Ga-Mn-based alloys by changing the chemical composition with considering the electron concentrations.

Comprehensive study on the through-process Goss texture evolution in Fe-3.78 wt.%Si grain oriented electrical steel

Cold rolled grain oriented steel is used in transformer cores due to its superior magnetic properties. Large Goss oriented grains develop after the final secondary recrystallization provide low hysteresis loss. The present study represents the development of Goss orientation after each processing stage of Fe-3.78 wt% Si steel with the help of electron backscatter diffraction and x-ray diffraction techniques. The Goss oriented grains developed during hot rolling and hot band annealing did not remain stable in cold rolling. On the other hand, shear bands developed inside {111}<112> component of γ-fiber texture during cold rolling. Partial recrystallization of the cold rolled sheet revealed that Goss oriented grains started evolving inside the shear bands of {111}<112> oriented grains. Intermediate annealing between cold rolling passes was found to be not essential to achieve Goss orientation in primary recrystallization. The optimum primary recrystallization temperature was in between 923 and 948 K where a significant amount of Goss oriented grains were present. Further, secondary recrystallization was attempted at different temperatures between 1173 and 1473 K. Grain boundary curvature of Goss oriented grains and all other grains after both primary and secondary recrystallization was studied. Despite the percentage of convex boundaries surrounding Goss oriented grains was found slightly higher than that around other grains, it was insufficient to cause abnormal grain growth.

Magnetic properties of Fe/parylene soft magnetic composites prepared via chemical vapor deposition

Iron-based soft magnetic composites with different contents of parylene were prepared by chemical vapor deposition (CVD), though this method, the edges and spikes can be coated with parylene. The morphology and magnetic properties of the materials are investigated. The self-lubricating parylene forms a thin and uniform insulating layer on the surface of iron particles, which reduces the magnetic loss of soft magnetic composite materials. The 4% parylene coated iron powder has high compression density, low hysteresis loss, excellent insulation performance, high resistivity and low eddy current loss. Compared with silicone resin and epoxy resin, the insulating layer formed by prylene has fewer holes and gaps, and the magnetic core loss is smaller.

Fabrication and Soft Magnetic Properties of Fe–Si–Cr Composites with Double-Insulating Layers Suitable for High-Frequency Power Applications

Soft magnetic composites (SMCs) are composed of alloy materials with the core and insulating layers as the shell. These composites exhibit high saturation magnetic sensitivity and low hysteresis loss, making them a promising material for various applications. The investigation of double layers is considered valuable as it can effectively address the issues of low resistivity and high dynamic loss that arise from non-uniform insulating layers in SMCs. In this study, Fe-Si-Cr/SiO2 particles with a core–shell heterostructure were produced via chemical vapor deposition (CVD). The Fe-Si-Cr/SiO2 materials were coated with different weight percentages (1–6%) of sodium silicate (SS). Subsequently, Fe-Si-Cr-based SMCs were synthesized through high-pressure molding and heat treatment. The effect of the SS weight percentage on microscopic changes and magnetic characteristics was investigated. These findings indicated that a concentration of 4 wt% of SS was the most effective at enhancing magnetic characteristics. The resultant SMCs exhibited high resistivity (21.07 mΩ·cm), the lowest total loss (P10 mt/300 kHz of 44.23 W/kg), a relatively high saturation magnetization (181.8 emu/g), and permeability (35.9). Furthermore, it was observed that the permeability exhibited stabilization at lower frequencies. According to these findings, the combination of CVD and double layers could lead to the further development of SMCs in a variety of applications.

Enhanced multiferroicity of Ho0.95Co0.05Fe0.95Ti0.05O3 by co-doping in HoFeO3 nanoparticle system

Nanocrystalline HoFeO3 is a potential multiferroic and will be more useful if its multiferroicity can be enhanced by improving the magnetic and electric ordering. In this regard, co-doping with Co and Ti, was considered in HoFeO3 (HFO) to enhance its magneto-electric behavior and thus synthesize a new monophasic multiferroic, Ho0.95Co0.05Fe0.95Ti0.05O3 (HCFTO). Both the pristine and doped HFO nanoparticles were synthesized in sol–gel route. Rietveld analyses of X-ray diffractograms, confirmed the formation of pure orthorhombic (Pnma) phase of both bare and doped HFO. Presence of the canted antiferromagnetism of bare HFO at room-temperature with antiferromagnetic transition at ∼ 637 K was confirmed in susceptibility vs. temperature variation and by the nature of MH loops. Interestingly, substantial enhancement of magnetism was observed in HCFTO compared to that of bare one, where the room-temperature maximum magnetization is enhanced by 73%. Dielectric strength of HFO (∼48) is also enhanced highly (∼3.4 times) in HCFTO (∼165), and the loss factor is lowered to nearly half. Current density vs. electric field (J-E) curve suggests the presence of polarization at room temperature with negligible leakage loss. Lower leakage loss of HCFTO indicates better multiferroicity than HFO. Direct measurement of ferroelectric loop shows the room-temperature ferroelectricity of bare HFO (Pmax ∼ 0.0041 µc/cm2) well improved (∼1.5 times) in the doped HCFTO (Pmax ∼ 0.0061 µc/cm2) with lower hysteresis loss. Room-temperature magnetoelectric coupling measurements, shows a high value (∼2.47%) of magnetocapacitance in the doped system, which is much higher (∼4.94 times) than the bare one (∼0.5%). All these properties of the sample clearly confirm the co-doping in the HoFeO3 nanoparticle system results in a considerable improvement in its magnetoelectric behavior, and this co-doped Ho0.95Co0.05Fe0.95Ti0.05O3 system can be a promising and potential magnetoelectric multiferroic for device applications.

Large reversible magnetocaloric effect across the first-order magneto-structural transition in (Mn0.45Fe0.55) (Ni0.6Co0.4) Si alloy

Magnetic materials with reversible magnetocaloric effect across their respective first-order magneto-structural transitions (MST) have vital significance for further advancement towards the ultimate goal of practical magnetic cooling applications. In this present study, the reversibility of the MST is investigated by analyzing the isofield curves under different minor and major thermal hysteresis loops and the isothermal curves under different magnetic field cycles. The reversibility of the magnetocaloric effect (MCE) depends upon the width of the nucleation energy barrier existing across the MST. Minor hysteresis loops are found to be minimizing the energy loss by preventing the nucleation of the martensite phase and can be easily returned to the austenite phase immediately while switching from cooling to heating. A large reversible isothermal magnetic entropy change ΔSM of −14.4 J kg−1 K−1 nearly at 322 K is observed for the (Mn0.45Fe0.55) (Ni0.6 Co0.4) Si alloy under a low magnetic field change of 3 T. The observed large reversible MCE, very low magnetic field-induced hysteresis loss, and large reversible RCeffe ∼ 155 J kg−1 will be beneficial for reducing the energy loss during several magnetic field cycles in practical cooling applications which makes this alloy promising for the development of efficient magnetic refrigerants.

Effect of pH values on the structural, morphological and sensing properties of ZnO nanostructure

In the present investigation ZnO thin films have been prepared by sol-gel spin coating technique with different pH values. The effect of pH values of precursor solution on the crystal structural, morphological and humidity sensing properties of ZnO nanostructures have been investigated using different characterization technique. The crystal structure and phase analysis has been examined by powder X-ray diffraction (PXRD) technique. The PXRD pattern clearly revealed the ZnO thin films have hexagonal wurtzite crystal structure. The average crystallite size of ZnO thin films have been calculated using Scherer formula and found to be ~24 nm to ~30 nm. The microstrain (ɛa) and (ɛc) of ZnO thin films for different pH values 8 and 11, have been calculated and found to be 7.59, 0.1017; 7.57, 0.1094 respectively. The scanning electron microscopy (SEM) image depicts the formation of spherical nanostructurewith diameter range 80 to 95 nm distributed throughout the surface. The atomic force microscopy (AFM) image also shows the spherical nanostructureconsistently distributed throughout the surface with diameter range 75 to 80 nm.It was also found that increasing the pH values from 8 to 11 modified the grains and grains boundary. The humidity sensing properties of ZnO thin films prepared from pH values of 8 to 11 and found to be lower hysteresis loss, less aging effect and good sensitivity in the range of 8.37 MΩ/%RH to 12.25 MΩ/%RH respectively

Comparison of two compounding techniques for carbon nanotubes filled natural rubbers through microscopic and dynamic mechanical characterizations

Natural rubber used in wave energy converters requires higher fatigue life and better energy harvesting efficiency to make it inexpensive compared to other renewable energy resources. Carbon nanotubes (CNTs) were extensively used to enhance the mechanical properties of natural rubber, however, its performance in a double-bonded shear condition was rarely investigated. In addition, the state of CNT dispersion was a critical factor for better energy harvesting efficiency and fatigue life. Therefore, this study was aimed to compare two different dispersion approaches in CNT synthesis so that better dynamic mechanical properties and lower hysteresis loss were achieved. One approach was done in the liquid state whereas the other one was carried out in dry condition. Although the former manifested a better CNT dispersion, no significant differences in terms of dynamic mechanical properties and dissipation losses compared to the latter compounding were obtained.

Improving the soft magnetic properties of binder jet printed iron-silicon alloy through boron addition

Fe–Si alloys are an essential class of soft magnetic materials due to their high magnetic permeability and low hysteresis loss. Increasing the Si content above 3 wt% promotes coarser grain sizes and greater electrical resistivity, thereby enhancing the magnetic properties, such as magnetic permeability and specific loss density. However, the increased silicon content makes the machining challenging. Additive manufacturing technologies enable production of near net shape Fe–Si alloys with high silicon content, practically eliminating the machining challenges. This work investigated the effects of Si content, which ranged from 3 to 5 wt%, and B content, which ranged from 0 to 0.25 wt%, on the microstructure and magnetic properties. The Fe–Si–B alloys were binder jet printed, where the sintering temperature was varied between 1200 and 1250 °C, and microstructure-magnetic property relationships were investigated by characterizing the magnetic permeability, intrinsic coercivity, grain size, and density. The Fe-5wt.%Si alloy with 0.25% B sintered at 1200 °C exhibited the highest magnetic relative permeability (4447) and the lowest intrinsic coercivity (47.8 A/m).