Crystallization mechanism and its correlation with structural and soft magnetic properties of FeSiBPCu nanocrystalline alloys

Correlation of crystallization mechanism with the structural and soft magnetic properties of FeSiBPCu nanocrystalline alloys has been investigated on the basis of Johnson–Mehl–Avrami kinetic model, transmission electron microscopy, and extended random anisotropy model. Pre-existent α-Fe clusters in melt-spun alloys with a size much smaller than critical nucleus size crystallize at a steadily increasing nucleation rate owing to the chain effect of rising constituent fluctuation. This unique crystallization mechanism leads to the formation of fine and uniform nanocrystallites and therefore superior soft magnetic properties. In contrast, pre-existent α-Fe clusters with a size approximate to the critical nucleus size nucleate gradually at the initial stage of crystallization process driven by thermal activation over the energy barrier of nucleation, and pre-existent α-Fe nanocrystallites with a size larger than critical nucleus size grow directly at the initial stage of crystallization process. Grains formed at the initial stage enlarge further in the subsequent crystallization process, which gives rise to a continuous decrease of the nucleation rate and the deterioration of soft magnetic properties.