Abstract
High-Cu-content (Cu-content > 1.3 at.%) nanocrystalline alloys exhibit wide heat-treatment windows and favorable soft magnetic properties due to the presence of pre-existing α-Fe nanocrystals. By fabricating ribbons with varying thicknesses to tailor cooling rates, distinct structural characteristics were achieved in Fe(82)B(16.5)Cu(1.5) alloy ribbons. Notably, the face-centered cubic (fcc) γ-Fe phase was identified in Fe-based nanocrystalline alloys. The precipitation of the fcc γ-Fe phase originates from a phase-selection mechanism under specific cooling conditions, while its retention in the as-quenched ribbon with a thickness of 27 μm is attributed to kinetic suppression during rapid cooling and the nanoscale stabilization effect. The formation of the fcc γ-Fe phase significantly reduced the saturation flux density (B(s)) and increased coercivity (H(c)), concurrently destabilizing the residual amorphous matrix. By suppressing the precipitation of the γ-Fe and Fe(3)B phases through precise control of ribbon thickness and annealing parameters, the alloy ribbon with a thickness of 16 μm achieved an optimal combination of B(s) (1.82 T) and H(c) (8.3 A/m). These findings on anomalous fcc γ-Fe phase precipitation provide novel insights into metastable phase engineering and offer structural design guidelines for alloys containing pre-existing α-Fe nanocrystals.