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 1a+b6, wherein a is an atomic % content of C and b is an atomic % content of S, B meeting 4.5x13.0, wherein x is an atomic % content of B, Cu meeting 0.2y1.5, wherein y is an atomic % content of Cu, Al meeting 0.5z2, 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.

Provided is a method for manufacturing soft magnetic iron powder.

A method for manufacturing soft magnetic iron powder, the method including ejecting high-pressure water to collide with a molten metal stream falling vertically downward, breaking up the molten metal stream into metal powder, and cooling the metal powder, in which, when a falling rate of the molten metal stream per unit time is defined as Qm (kg/min) and an ejection rate of high-pressure water per unit time is defined as Qaq (kg/min), a mass ratio (Qaq/Qm) is 50 or more, and a total content of ferrous constituents (Fe, Ni, and Co) is 76 at % or more.

A soft magnetic alloy includes a composition of (Fe.sub.(1-(+))X1.sub.X2.sub.).sub.(1-(a+b+c+d+e+f+g))M.sub.aTi.sub.bB.sub.cP.sub.dSi.sub.eS.sub.fC.sub.g. X1 is one or more of Co and Ni. X2 is one or more of Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O, and rare earth elements. M is one or more of Nb, Hf, Zr, Ta, Mo, W, and V. 0.020a+b0.140, 0.001b0.140, 0.020<c0.200, 0.010d0.150, 0e0.060, a0, f0, g0, a+b+c+d+e+f+g<1, 0, 0, and 0+0.50 are satisfied. The soft magnetic alloy has a nanohetero structure or a structure of Fe-based nanocrystalline.

The iron alloy particle is a particle including an iron alloy, and 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.

A powder magnetic core capable of achieving a low loss in a high frequency range is provided. A powder magnetic core according to the present disclosure is a powder magnetic core in which a magnetic powder is bonded via a binder layer. A volume filling percentage of the magnetic powder included in the powder magnetic core is 85 volume % or higher, and a value obtained by dividing a BET specific surface area (m.sup.2/g) of the powder magnetic core by a specific surface area (m.sup.2/g) calculated using outer dimensions of the powder magnetic core is 5000 or less.

An inductor has a main magnet core, a coil mounted around the main magnet core, and a residual magnet encapsulating the main magnet core and partially encapsulating the coil. The main magnet core is made of a main magnet core powder containing amorphous iron base material and nickel base material powders. The residual magnet is made of a residual magnet powder containing a main magnet powder and a soft magnet powder including an iron-silicon-chromium alloy powder and a carbonyl iron powder. Thus, through a low-loss feature of the amorphous iron base material and nickel base material powders, a loss of the main magnet core is reduced. Furthermore, a magnetic permeability of the residual magnet matches a magnetic permeability of the main magnet core. A magnetic leakage is further avoided, and the alternating current resistance is reduced. A quality factor and a conversion efficiency are enhanced.

A method of manufacturing an Fe-based amorphous alloy ribbon includes forming a coated film of a molten alloy on a peripheral surface of a chill roll that has been subjected to polishing using a polishing brush roll, cooling the coated film on the peripheral surface, and then winding the Fe-based amorphous alloy ribbon, which has been peeled off by a peeling means, on a wind-up roll, to obtain a wound body of an Fe-based amorphous alloy ribbon.

The polishing brush roll includes a roll axis member and a polishing brush that is equipped with a plurality of brush bristles and satisfies the following condition (1) and condition (2) while rotating axially in a reverse direction to the chill roll. Condition (1): Free length of brush bristles is more than 30 mm but no more than 50 mm. Condition (2): Density of brush bristles at the brush bristle tip is more than 0.30 bristles/mm.sup.2 but no more than 0.60 bristles/mm.sup.2.

Disclosed is an iron-based amorphous alloy Fe.sub.aB.sub.bSi.sub.cRE.sub.d, wherein a, b, and c represent, in atomic percentages, the contents of corresponding components, respectively; 83.0?a?87.0, 11.0<b<15.0, 2.0?c?4.0, and a+b+c=100; and d is the concentration of RE in the iron-based amorphous alloy, i.e. 10 ppm?d?30 ppm. The iron-based amorphous alloy has a saturation magnetic induction intensity of no less than 1.63 T, and same can be used to manufacture a magnetic core material for power transformers, motors and inverters.

An amorphous metal ribbon includes a plurality of laser irradiation mark rows each including a plurality of laser irradiation marks arranged in a row, in which when a distance between the laser irradiation mark rows that are adjacent to each other is set as d1, a distance between the laser irradiation marks in the laser irradiation mark row is set as d2, a diameter of the laser irradiation mark is set as d3, and a number density D of the laser irradiation marks is set as (1/d1)?(1/d2), the number density D of the laser irradiation marks is 0.05 pieces/mm.sup.2 or more and 0.50 pieces/mm.sup.2 or less, and when an area occupancy rate A of the laser irradiation marks is set as D?(d3/2).sup.2???100, the area occupancy rate A of the laser irradiation marks is 0.0035% or more and 0.040% or less.

The present invention achieves an object of continuously supplying a melt from a melt nozzle over a long period of time by adjusting the contents of Mn and S in an FeBSiC-type amorphous alloy ribbon. An amorphous alloy ribbon of the present invention includes a composition containing Fe, Si, B, C, Mn, S, and inevitable impurities, the composition containing, with respect to 100.0 atm % of the total amount of Fe, Si, B, and C, 3.0 atm % or more and 10.0 atm % or less of Si, 10.0 atm % or more and 15.0 atm % or less of B, and 0.2 atm % or more and 0.4 atm % or less of C, the amorphous alloy ribbon having a content ratio of Mn of more than 0.12 mass % and less than 0.15 mass %, and a content ratio of S of 0.0036 mass % or more and less than 0.0045 mass %, the amorphous alloy ribbon having a thickness of 10 m or more and 40 m or less, and a width of 100 mm or more and 300 mm or less.