Formation of nanostructured Fe88Co12 alloy using high energy ball milling

•The research is an attempt to synthesise Fe88Co12 alloy employing a cost-effective ball milling route.•The synthesis route was performed uniquely by choosing an open-air environment.•The appreciable saturation magnetization (91.90 emu/g) and appropriate coercivity value (364.08 G) for the alloy was obtained for 24 h milling time, affirming its potential application as soft magnetic material. The structural and magnetic properties of nanocrystalline Fe88Co12 powders were synthesized by utilizing a planetary high-energy ball mill. Considering the massive industrial scale of applications, mechanical ball milling remains the most common and efficient technology for nanomaterials manufacture. The effects of performing FeCo alloy synthesis in air rather than the conventional argon atmosphere are investigated with the goal of developing cost-effective processes. X-ray diffractometer (XRD), X-ray photoelectron spectroscopy(XPS), Scanning electron microscope (SEM), and the vibrating sample magnetometer (VSM) have been used to monitor the changes in microstructural and magnetic properties with different milling times. After 24 h of milling, the production of Fe88Co12 alloy is complete. SEM was used to examine grain morphologies at various phases of development. In terms of milling time, saturation magnetization and coercive force determined through hysteresis curves are examined.