Magnetic properties evaluation of Fe-based amorphous alloys synthesized via spark plasma sintering

•Fe77.7Si8B10P4Cu0.3 amorphous powder was successfully prepared by gas atomization.•High density powder compacts with amorphous can be obtained by spark plasma sintering.•Powder compacts exhibits high relative density (94%), saturated magnetic flux density (1.34 T), low coercivity (2.3 Oe), and high permeability (163 stable up to 20 kHz).•The effect of sintering temperature on the magnetic properties was discussed based on density and structure. Fe77.7Si8B10P4Cu0.3 amorphous powder compacts with high relative density (ρr = 94%), high saturated magnetic induction (Bs = 1.34 T), and high permeability (μ = 163 at 20 kHz) were fabricated by spark plasma sintering. In this work, Fe77.7Si8B10P4Cu0.3 spherical amorphous powders with good amorphous forming ability were prepared by regulating the material composition and the particle size distribution by gas atomization at first. The effect of sintering temperature (Ts) on the structure and magnetic properties of powder compacts was systematically investigated. The powder compacts sintered at Ts of 696–712 K were found to remain amorphous structure and exhibit optimal structural and magnetic performance, due to the high temperature and high pressure employed in SPS with high heating rate. These results are promising for the applications of Fe-based amorphous powder alloys in soft magnetic devices requiring tens of kilo-hertz frequency.