Abstract The prevalence of wide‐bandgap (WBG) semiconductors allows modern electronic devices to operate at much higher frequencies. However, development of soft magnetic materials with high‐frequency properties matching the WBG‐based devices remains challenging. Here, a promising nanocrystalline–amorphous composite alloy with a normal composition Fe 75.5 Co 0.5 Mo 0.5 Cu 1 Nb 1.5 Si 13 B 8 in atomic percent is reported, which is producible under industrial conditions, and which shows an exceptionally high permeability at high frequencies up to 36 000 at 100 kHz, an increase of 44% compared with commercial FeSiBCuNb nanocrystalline alloy (25 000 ± 2000 at 100 kHz), outperforming all existing nanocrystalline alloy systems and commercial soft magnetic materials. The alloy is obtained by a unique magnetic‐heterogeneous nanocrystallization mechanism in an iron‐based amorphous alloy, which is different from the traditional strategy of nanocrystallization by doping nonmagnetic elements (e.g., Cu and Nb). The induced magnetic inhomogeneity by adding Co atoms locally promotes the formation of highly ordered structures acting as the nuclei of nanocrystals, and Mo atoms agglomerate around the interfaces of the nanocrystals, inhibiting nanocrystal growth, resulting in an ultrafine nanocrystalline–amorphous dual‐phase structure in the alloy. The exceptional soft magnetic properties are shown to be closely related to the low magnetic anisotropy and the unique spin rotation mechanism under alternating magnetic fields. 

Ultrahigh Permeability at High Frequencies via A Magnetic‐Heterogeneous Nanocrystallization Mechanism in an Iron‐Based Amorphous Alloy

Fe-based amorphous/nanocrystalline alloys exhibit excellent soft magnetic properties, including high saturation magnetic flux density ( Bs), high permeability, low coercivity ( Hc), and low magnetostriction. They are utilized in distribution transformers, transformers, reactors, and other devices. As green, energy-saving, and environmentally friendly materials, their application fields have more possibilities. In this paper, the development history, composition design principle, heat treatment process, magnetic properties, and annealing brittleness of Fe-based amorphous/nanocrystalline alloys are introduced.

Advances in Fe-based amorphous/nanocrystalline alloys

Superior high-frequency performances of Fe-based soft-magnetic nanocrystalline alloys

Analysis of surface roughness and oxidation of FeNi-based metal amorphous nanocomposite alloys

Influence of microstructure and anisotropy on the high-frequency soft magnetic properties of nanocrystalline FeSiBNbCuP alloys

The deterioration of magnetic softness caused by surface crystallization is a common problem in Fe-based amorphous and nanocrystalline alloys. However, we found that the surface crystallization of Fe76Si13B8Nb2-xMoxCu1 (x = 0,1,2) amorphous alloys has negligible effects on the onset precipitation temperature, nucleation, and growth activation energy of α-Fe(Si) phase, thus forming a nanocrystalline structure similar to that of the fully amorphous sample after proper heat treatment. The ultrafine nano-grains uniformly precipitated in the ribbons due to the competitive growth of numerous tiny pre-crystals/clusters near the surface and the internal grain refinement caused by refractory elements, which helps to form regular magnetic domains, thereby good magnetic softness comparable to that of the fully amorphous sample was obtained. This work provides guidance for eliminating the deteriorating effect of surface crystallization on magnetic properties and expanding the industrial application of surface-crystallized Fe-based amorphous alloys.

Enhanced magnetic softness of surface-crystallized Fe-Si-B-Nb-Mo-Cu amorphous alloys via competitive growth of surface pre-crystals/clusters

High-frequency magnetic characteristics and operating thermal stability of industrialized Fe76Si13B8Nb2Cu1 nanocrystalline alloy

Good high-frequency magnetic softness and thermal stability are very important for the wide application of Fe-based nanocrystalline alloys. The present work reports the influence of Mn-doping and rapid annealing on the magnetic softness, nano-structure, and magnetic-microstructure of Fe76−xSi13B8Nb2Cu1Mnx (x = 0, 1, 2, 3, and 4) alloys. It was found that the Fe74Si13B8Nb2Cu1Mn2 alloy exhibits a superior magnetic softness with the high-saturation magnetic induction of 1.32 T and a large permeability at 100 kHz of over 15,000 at a large annealing-temperature region of 120 °C. The microstructure and magnetic domains characterization indicate that the good magnetic softness and thermal stabilization can be ascribed to the superb nano-structural stability caused by the Mn doping and rapid annealing at elongated temperatures, which can maintain a fine and high number density α-Fe(Si) nano-grains and facilitate the formation of regular and wide domains.

Rapid Annealing Optimizing Magnetic Softness and Thermal Stability of Mn-Substituted Fe-Based Nanocrystalline Alloys

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Enhanced magnetic softness of surface-crystallized Fe-Si-B-Nb-Mo-Cu amorphous alloys via competitive growth of surface pre-crystals/clusters

High-frequency magnetic characteristics and operating thermal stability of industrialized Fe76Si13B8Nb2Cu1 nanocrystalline alloy

Rapid Annealing Optimizing Magnetic Softness and Thermal Stability of Mn-Substituted Fe-Based Nanocrystalline Alloys