Ultra-low cost and energy-efficient production of FePCSi amorphous alloys with pretreated molten iron from a blast furnace

Due to the high sensitivity of amorphous forming ability on purity, Fe-based amorphous alloys are always made with high-purity raw materials which are energy wasting for purification and expensive, thereby limiting their wider application. Here, we proposed an ultra-low cost and energy-efficient production process for Fe-based amorphous alloys, with pretreated molten iron from the blast furnace. Fe_x(P₁₀C₉Si₁)_5–0.05x(x = 76–82) amorphous alloys with excellent manufacturability and magnetic properties were successfully prepared with the new process. The impurities containing C, P, and Si in the molten iron from a blast furnace were used as useful components, while other minor impurities like Ti and Mn do not apparently affect the GFA and magnetic properties. Attractive magnetic properties, including low H_c of 3.1–5.1 A/m, high μ_e of 6.1–8.4 × 10³ at 1 kHz, high B_s of 1.25–1.48 T were achieved in ribbon samples after optimal annealing. Rod samples with a diameter up to 1.5 mm were readily prepared and exhibit high strength of 3.37 GPa. The ultra-low cost, energy saving effects and excellent soft magnetic properties will render the production process a new generation for Fe-based amorphous alloys and widen the applications.