Preparation of high performance soft magnetic alloy Fe-4Si-0.8P by metal injection molding

•Fe-4Si-0.8P soft magnetic alloy was prepared by metal injection molding.•The sample with nearly full density was obtained at 1300 °C for 4 h.•B6000 of 1.59 T, μm of 2467 and Hc of 130 A/m have been obtained.•Relative high resistivity of 81.2μΩ·cm was acquired.

Fe-4Si-0.8P soft magnetic alloy was prepared by metal injection molding (MIM). Ferrophosphorus liquid phase sintering promoted densification and enhanced magnetic properties. The sample with nearly full density, the saturation induction of 1.59 T, maximum permeability of 2467, coercive force of 130 A/m and resistivity of 81.2 μΩ·cm was obtained at 1300 °C for 4 h. Competitive properties contributed toward achieving low magnetic losses. Therefore, MIM Fe-4Si-0.8P can be widely used in the field of magnetic materials.

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