A soft magnetic alloy or the like combining high saturated magnetic flux density, low coercive force and high magnetic permeability μ′ having the composition formula (Fe.sub.(1−(α+β))X1.sub.αX2.sub.β).sub.(1−(a+b+c+d+e))B.sub.aSi.sub.bC.sub.cCu.sub.dM.sub.e. X1 is one more elements selected from the group consisting of Co and Ni, X2 is one or more elements selected from the group consisting of Al, Mn, Ag, Zn, Sn, As, Sb, Bi, N, O and rare earth elements, and M is one or more elements selected from the group consisting of Nb, Hf, Zr, Ta, Ti, Mo, W and V. 0.140<a≤0.240, 0≤b≤0.030, 0<c<0.080, 0<d≤0.020, 0≤e≤0.030, α≥0, β≥0, and 0≤α+β≤0.50 are satisfied.

An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.

An Fe-based amorphous alloy ribbon reduced in iron loss, less deformed, and highly productive in a condition of a magnetic flux density of 1.45 T is provided. One aspect of the present disclosure provides an Fe-based amorphous alloy ribbon having first and second surfaces, and is provided with continuous linear laser irradiation marks on at least the first surface. Each linear laser irradiation mark is formed along a direction orthogonal to a casting direction of the Fe-based amorphous alloy ribbon, and has unevenness on its surface. When the unevenness is evaluated in the casting direction, a height difference HL×width WA calculated from the height difference HL between a highest point and a lowest point in a thickness direction of the Fe-based amorphous alloy ribbon and the width WA which is a length of the linear irradiation mark on the first surface is 6.0 to 180 μm.sup.2.

To obtain a magnetic core having an improved withstand voltage property while maintaining a high relative magnetic permeability, and the like. The magnetic core contains large particles observed as soft magnetic particles having a Heywood diameter of 5 μm or more and 25 μm or less and small particles observed as soft magnetic particles having a Heywood diameter of 0.5 μm or more and less than 5 μm in a cross section. C1<C2 is satisfied in which an average circularity of the small particles close to the large particles is C1 and an average circularity of all small particles observed in the cross section including small particles not close to the large particles is C2. The small particles close to the large particles are defined as small particles whose distance from centroids of the small particles to a surface of the large particles is 3 μm or less.

A consolidated metallic glass structure is formed by fabricating [200] metallic glass nanoparticles with a solution-phase synthesis that provides coated metallic glass nanoparticles with a polymer ligand layer; stripping [202] the polymer ligand layer from the coated metallic glass nanoparticles to provide bare metallic glass nanoparticles; depositing [204] the bare metallic glass nanoparticles on a substrate to provide a deposited structure; and sintering [206] the deposited structure with heat and/or pressure to provide the consolidated metallic glass structure. The metallic glass nanoparticles are preferably composed substantially of nickel and boron, iron and boron, or cobalt and boron.

Provided is a soft magnetic alloy which has high saturation flux density and low coercivity and is represented by the compositional formula (Fe.sub.(1−(α+β))X1.sub.αX2.sub.β).sub.(1−(a+b+c+d+e+f))M.sub.aP.sub.bSi.sub.cCu.sub.dX3.sub.eB.sub.f, wherein X1 is at least one element selected from the group consisting of Co and Ni, X2 is at least one element selected from the group consisting of Ti, V, Mn, Ag, Zn, Al, Sn, As, Sb, Bi, and rare earth elements, X3 is at least one element selected from the group consisting of C and Ge, and M is at least one element selected from the group consisting of Zr, Nb, Hf, Ta, Mo, and W, and wherein 0.030≤a≤0.120, 0.010≤b≤0.150, 0≤c≤0.050, 0≤d≤0.020, 0≤e≤0.100, 0≤f≤0.030, α≥0, β≥0, and 0≤α+β≤0.55.

One embodiment of the present invention provides an Fe-based amorphous alloy ribbon for an Fe-based nanocrystalline alloy, the Fe-based amorphous alloy ribbon being a cooled body of a molten metal that has been applied to a surface of a chill roll, wherein the Fe-based amorphous alloy ribbon includes a recess having a depth of 1 μm or more in a 0.647 mm×0.647 mm region located in a central part, in the ribbon width direction, of a ribbon surface, which is a cooled surface, in which a maximum area of the recess having a depth of 1 μm or more is 3000 μm.sup.2 or less; and a method of manufacturing the same.

A method for manufacturing an alloy ribbon piece capable of manufacturing a nanocrystalline alloy ribbon piece is provided. The method for manufacturing an alloy ribbon piece according to the present disclosure is a method for manufacturing an alloy ribbon piece obtained by crystallizing an amorphous alloy ribbon piece, and includes: preparing the amorphous alloy ribbon piece; sequentially heating the amorphous alloy ribbon piece from one end to an intermediate position toward another end to a temperature range equal to or more than a crystallization starting temperature, and stopping the heating when heating the amorphous alloy ribbon piece up to the intermediate position to the temperature range; and heating a region on the other end side with respect to the intermediate position of the amorphous alloy ribbon piece to the temperature range equal after the stopping of the heating in the sequentially heating.

A method for manufacturing a nanocrystalline alloy ribbon piece with high productivity is provided. The method according to the present disclosure is a method for manufacturing an alloy ribbon piece obtained by crystallizing an amorphous alloy ribbon piece, and includes: preparing the amorphous alloy ribbon piece; sequentially heating the ribbon piece from one end to an intermediate position toward another end to a temperature range equal to or more than a crystallization starting temperature, and stopping the heating when heating the ribbon piece up to the intermediate position; and sequentially heating the ribbon piece from the other end to a position immediately before the intermediate position to the temperature range. In the sequentially heating the ribbon piece from the other end, the ribbon piece is heated up to the position immediately before the intermediate position after the heating is stopped in sequentially heating the ribbon piece from the one end.

An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.