Fe-based amorphous alloys with superior soft-magnetic properties prepared via smelting reduction of high-phosphorus oolitic iron ore

Fe-based amorphous alloys generally suffer from the impurities in industrial raw materials and the high cost of pure raw materials. In this work, a revolutionary way for preparing Fe-based amorphous alloys from the re-fractory high-phosphorus oolitic iron ore with the combination of smelting reduction and melt-spinning was proposed for the simultaneously utilization of Fe and P elements. By using the smelting reduction, Fe-P alloys with high Fe and P recovery rate of 99% and 92% can be obtained, and the C content in the resultant Fe-P alloys can be accurately tailored by adjusting the C/O ratio. For the implementation of the developed process, the reduced Fe-P alloys with significantly different C content and the corresponding Fe83P3C1Si2B11, Fe76P5C3.8-Si5.7B9.5 and Fe80P10C9Si1 (at. %) amorphous alloys with close C content were chosen. These resultant alloys all exhibit high AFA, low lic and high mu e as well as wide annealing window comparable to that of the alloys prepared with pure raw materials, demonstrating the feasibility of the developed process for energy-saving and resource-friendly production of soft-magnetic materials via smelting reduction of iron ores.

Automated summary

A revolutionary method for preparing Fe-based amorphous alloys from high-phosphorus oolitic iron ore was proposed, combining smelting reduction and melt-spinning. The developed process showed the feasibility of energy-saving and resource-friendly production of soft-magnetic materials.