A nanocomposite comprising crystalline grains in an amorphous matrix, the crystalline grains comprising an iron (Fe)-nickel (Ni) compound and being separated from one another by the amorphous matrix; and one or more barriers between the crystalline grains and the amorphous matrix, the barriers being configured to inhibit growth of the crystalline grains during forming of the crystalline grains, a barrier of the one or more barriers being between a crystalline grain and the amorphous matrix; wherein the amorphous matrix comprises an increased resistivity relative to a resistivity of the crystalline grains; and wherein the amorphous matrix is configured to reduce losses of the crystalline grains caused by a change in a magnetic field applied to the crystalline grains relative to losses of the crystalline grains that occur without the amorphous matrix.

The iron alloy particle is a particle including an iron alloy. The particle includes multiple mixed-phase particles, each including nanocrystals of 10 nm or more and 100 nm or less (i.e., from 10 nm to 100 nm) in crystallite size and an amorphous phase; and a grain boundary layer between the mixed-phase particles. Also, the iron alloy has a composition containing Fe, Si, P, B, C, and Cu.

The present disclosure relates to an iron (Fe)-based amorphous soft magnetic alloy and a method for manufacturing the soft magnetic alloy. According to the present disclosure, there is provided an Fe-based soft magnetic alloy including C and S meeting 1≥a+b≥6, wherein a is an atomic % content of C and b is an atomic % content of S, B meeting 4.5≥x≥13.0, wherein x is an atomic % content of B, Cu meeting 0.2≥y≥1.5, wherein y is an atomic % content of Cu, Al meeting 0.5≥z≥2, wherein z is an atomic % content of Al, and a remaining atomic % content of Fe and other inevitable impurities, wherein the Fe-based soft magnetic alloy includes a micro-structure, and wherein the micro-structure includes a crystalline phase with a mean crystalline grain size ranging from 15 nm to 50 nm in an amorphous base.

An Fe-based nano-crystalline alloy formed from an alloy composition of (FeE).sub.(100-X-Y-Z)B.sub.XP.sub.YCu.sub.Z having an amorphous phase as a main phase, wherein 79≦100-X-Y-Z≦86 atomic %, 4≦X≦9 atomic %, 1≦Y≦10 atomic %, and 0.5≦Z<1.2 atomic %, and wherein (FeE) includes Fe and at least one element selected from the group consisting of Ti, Zr, Hf, Nb, Ta, Mo, W, Cr, Al, Mn, Ag, Zn, Sn, As, Sb, Bi, Y, N, O and a rare-earth element, wherein a combined total of said at least one element selected from the group consisting of Ti, Zr, Hf, Nb, Ta, Mo, W, Cr, Al, Mn, Ag, Zn, Sn, As, Sb, Bi, Y, N, O and a rare-earth element is in an amount of 3 atomic % or less relative to the whole composition.

A magnetic particle includes a magnetic metal particle having a plurality of phases. The plurality of phases include an Fe-based phase and an Fe.sub.3O.sub.4 phase. An area ratio of the Fe.sub.3O.sub.4 phase in which the Fe.sub.3O.sub.4 phase occupies in the plurality of phases is less than 50%.

A magnetic particle includes a magnetic metal particle, and an oxide film formed on a surface of the magnetic metal particle, wherein the magnetic metal particle includes a single crystalline zone containing an Fe component, and the oxide film includes an amorphous zone containing an Fe component. The single crystalline zone may include an α-Fe phase.

An Fe—Si—B—C-based amorphous alloy ribbon as thick as 20-30 μm having a composition comprising 80.0-80.7 atomic % of Fe, 6.1-7.99 atomic % of Si, and 11.5-13.2 atomic % of B, the total amount of Fe, Si and B being 100 atomic %, and further comprising 0.2-0.45 atomic % of C per 100 atomic % of the total amount of Fe, Si and B, except for inevitable impurities has a stress relief degree of 92% or more.

The method heats the metal foil made of amorphous soft magnetic material while bringing the metal foil into close contact with a placement surface of a metal base such that the metal foil conforms to the placement surface, to crystallize the amorphous soft magnetic material of the metal foil into nano-crystal soft magnetic material. In the crystallization, the metal foil is heated at a heating temperature to crystallize the amorphous soft magnetic material, the heating temperature being higher than or equal to a crystallization starting temperature at which the amorphous soft magnetic material crystallizes into nano-crystal soft magnetic material and allowing a temperature of the placement surface to be lower than a temperature of the metal foil having temperature rise due to heat generated by self-heating during crystallization, and the heat generated by self-heating of the metal foil during crystallization is absorbed by the base.

The present invention is to provide powder made of iron-based metallic glass, the corrosion resistance of which is improved over the conventional powder made of iron-based metallic glass. The basic composition includes a group of iron-based metallic elements that predominantly has Fe, a group of metalloid elements that consists of Si, B, P, and C, and a little amount of a group of elements for improving the degree of supercooling that consists of either or both of Nb and Mo. The powder made of the iron-based metallic glass is obtained by adding to the basic composition an element for improving the corrosion resistance. The obtained powder made of the iron-based metallic glass has an excellent corrosion resistance, an excellent magnetic property, and an excellent insulating property.

A magnetic core includes a nanocrystalline alloy ribbon having a composition represented by FeCu.sub.xB.sub.ySi.sub.zA.sub.aX.sub.b, where 0.6≤x<1.2, 10≤y≤20, 0≤(y+z)≤24, and 0≤a≤10, 0≤b≤5, all numbers being in atomic percent, with the balance being Fe and incidental impurities, and where A is an optional inclusion of at least one element selected from Ni, Mn, Co, V, Cr, Ti, Zr, Nb, Mo, Hf, Ta and W, and X is an optional inclusion of at least one element selected from Re, Y, Zn, As, In, Sn, and rare earth elements. The nanocrylstalline alloy ribbon has a local structure such that nanocrystals with average particle sizes of less than 40 nm are dispersed in an amorphous matrix and are occupying more than 30 volume percent of the ribbon.