Soft magnetic alloy powder includes plurality of soft magnetic alloy particles of soft magnetic alloy represented by composition formula (Fe.sub.(1−(α+β))X1.sub.αX2.sub.β).sub.(1−(a+b+c++e+f+g))M.sub.aB.sub.bP.sub.cSi.sub.dC.sub.eS.sub.fTi.sub.g, wherein X1 represents Co and/or Ni; X2 represents at least one selected from group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O, and rare earth elements; M represents at least one selected from group consisting of Nb, Hf, Zr, Ta, Mo, W, and V; 0.020≤a≤0.14, 0.020<b≤0.20, 0<c≤0.15, 0≤d≤0.060, 0≤e≤0.040, 0≤f≤0.010, 0≤g≤0.0010, α≥0, β≥0, and 0≤α+β≤0.50 are satisfied, wherein at least one of f and g is more than 0; and wherein soft magnetic alloy has a nano-heterostructure with initial fine crystals present in an amorphous substance; and surface of each of the soft magnetic alloy particles is covered with a coating portion including a compound of at least one element selected from group consisting of P, Si, Bi, and Zn.

An alloy composition, a Fe-based nano-crystalline alloy and a manufacturing method thereof, and a magnetic component are disclosed. The expression of the alloy composition is Fe.sub.aV.sub.αB.sub.bSi.sub.cP.sub.xC.sub.yCu.sub.z and 79≤a≤91 at %, 5≤b≤13 at %, 0≤c≤8 at %, 1≤x≤8 at %, 0≤y≤5 at %, 0.4≤z≤1.4 at %, 0<α<5 at % and 0.08≤z/x≤0.8(at % is atomic percent). The Fe-based nano-crystalline alloy is manufactured by subjecting the alloy composition to crystallization heat treatment. Even if the heating speed upon crystallization heat treatment is slow, or there is a deviation in the temperature reached, a Fe-based nano-crystalline alloy with high saturation magnetic induction intensity and excellent soft magnetic property can still be easily obtained from the alloy ingredients of the present invention. Moreover, the present invention provides a magnetic component manufactured using the Fe-based nano-crystalline alloy.

A compression molded core contains a plurality of soft magnetic material powders. A first powder and a second powder in the plurality of powders satisfy D1>D2, 0.23≤(D1−D2)/D1<0.6, D1≤7 μm, and 3 μm≤DT≤5.7 μm. D1 is the median diameter, which is a particle size at which the integrated particle diameter distribution from the small particle size side is 50% in a volume-based particle size distribution measured by a laser diffraction/scattering method, of the first powder and is maximum among median diameters; D2 is the median diameter D2 of the second powder and is minimum among median diameters; and DT is determined using the weight rate R1 of the first powder and the weight rate R2 of the second powder by R1×D1+R2×D2.

A coil component includes a magnetic portion that includes metal particles and a resin material, a coil conductor embedded in the magnetic portion, and outer electrodes electrically connected to the coil conductor. The average particle diameter of the metal particles in the magnetic portion is 1 μm or more and 5 μm or less, and the CV value of the metal particles is 50% or more and 90% or less.

A metal magnetic particle provided with an oxide layer on a surface of an alloy particle containing Fe and Si. The oxide layer has a first oxide layer, a second oxide layer, and a third oxide layer from a side of the alloy particle. All of the first oxide layer, the second oxide layer, and the third oxide layer contain Si. Also, in line analysis of element content by using a scanning transmission electron microscope-energy dispersive X-ray spectroscopy, the first oxide layer is a layer having Fe content smaller than Si content in the alloy particle, the second oxide layer is a layer having Fe content larger than the Si content in the alloy particle, and the third oxide layer is a layer having Fe content smaller than the Si content in the alloy particle.

The soft magnetic alloy of the present disclosure is represented by a composition formula of Fe.sub.aSi.sub.bB.sub.cCu.sub.dM.sub.e where M is at least one type of element selected from a group consisting of Nb, Mo, V, Zr, Hf, and W, and the formula satisfies 82.5≤a≤86, 0.3≤b≤3, 12.5≤c≤15.0, 0.05≤d≤0.9, and 0≤e<0.4 in at %. The soft magnetic alloy includes a structure that has a crystal grain with a grain diameter of 60 nm or less in an amorphous phase.

An insulating material coated soft magnetic powder, which is a powder body of an insulating material coated soft magnetic particle 1, includes: a core particle 2 including a base portion 2a that includes a soft magnetic material, and an oxide film 2b that is provided on a surface of the base portion 2a and contains an oxide of an element contained in the soft magnetic material, and an insulating film 3b in which a plurality of insulating nanoparticles 3a are attached to the core particle 2. A particle size of each nanoparticle 3a is 1/50,000 or more and 1/100 or less, relative to a particle size of the core particle 2, and after being subjected to a heat treatment in which the core particle 2 is heated at a sintering temperature or higher, a specific resistance after the heat treatment is 110% or more of a specific resistance before the heat treatment.

An inductor is disclosed, the inductor comprising: a T-shaped magnetic core, being made of a material comprising an annealed soft magnetic metal material and having a base and a pillar integrally formed with the base, wherein μC×Hsat≥1800, where μC is a permeability of the T-shaped magnetic core, and Hsat (Oe) is a strength of the magnetic field at 80% of μC0, where μC0 is the permeability of the T-shaped magnetic core when the strength of the magnetic field is 0.

An alloy is provided which consists of Fe.sub.100−a−b−c−d−x−y−zCu.sub.aNb.sub.bM.sub.c T.sub.dSi.sub.xB.sub.yZ.sub.z and up to 1 at % impurities, M being one or more of the elements Mo, Ta and Zr, T being one or more of the elements V, Mn, Cr, Co and Ni, Z being one or more of the elements C, P and Ge, 0 at %≤a<1.5 at %, 0 at %≤b<2 at %, 0 at %≤(b+c)<2 at %, 0 at %≤d<5 at %, 10 at %<x<18 at %, 5 at %<y<11 at % and 0 at %≤z<2 at %. The alloy is configured in tape form and has a nanocrystalline structure in which at least 50 vol % of the grains have an average size of less than 100 nm, a hysteresis loop with a central linear region, a remanence ratio Jr/Js of <0.1 and a coercive field strength H.sub.c to anisotropic field strength Ha ratio of <10%.

A coil component includes: a magnetic body part and a cover part covering one side of a magnetic layer part; and a coil part embedded in the magnetic body part. The magnetic body part is comprised of the following two types of layers: (A) an oblate soft magnetic grain-containing layer, and (B) a spherical grain-containing layer, wherein layer (A) extends over the entire range of the magnetic body part except for a portion including the coil part in a direction perpendicular to an axis direction of the coil part, layer (B) adjoins layer (A) in the axis direction. The cover part is constituted by multiple layers including one or more of layer(s) (A) and one or more of layer(s) (B) and extending over the entire range of the magnetic body part in the direction perpendicular to the axis direction.