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<p><i>Fe</i>-rich borides in the <i>Fe-B</i> system are difficult to stabilize under non-equilibrium conditions because of strong phase competition and complex transformation pathways. In this study, powders were synthesized by mechanical milling of a nominal Fe<sub>80</sub>B<sub>20</sub> (wt %) mixture, focusing on how structural evolution and defect formation affect the magnetic behavior. X-ray diffraction combined with Rietveld refinement shows that after 4&#xa0;h of milling, the final product is primarily composed of a metastable, <i>Fe</i>-rich body-centered cubic Fe<sub>1.8</sub>B<sub>0.2</sub> phase (~ 90%), coexisting with a minor <i>α-Fe(P)</i> solid solution (~ 10%). This constituent phase assembly forms far from equilibrium and highlights the role of sustained mechanical deformation in promoting partial metalloid incorporation into the iron lattice. As milling progresses, the microstructure undergoes continuous grain refinement together with a steady increase in defect density and internal strain. These changes play a key role in shaping the magnetic response, leading to soft magnetic behavior with low coercivity and stable permeability, governed by the competition between exchange interactions and defect-related pinning effects. Overall, the results highlight how mechanical milling can be used to stabilize metastable phases and tune structure–property relationships in <i>Fe-B</i> systems through controlled microstructural engineering.</p>

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Scalable production of Fe1.8B0.2 powders: high phase purity, soft magnetism, and mechanical stability

  • 期刊论文

  • 发表日期：

    2026年6月18日

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  • Sihem Benaissa,
  • Wassila Tebib,
  • Saida Boukeffa

摘要

Fe-rich borides in the Fe-B system are difficult to stabilize under non-equilibrium conditions because of strong phase competition and complex transformation pathways. In this study, powders were synthesized by mechanical milling of a nominal Fe80B20 (wt %) mixture, focusing on how structural evolution and defect formation affect the magnetic behavior. X-ray diffraction combined with Rietveld refinement shows that after 4 h of milling, the final product is primarily composed of a metastable, Fe-rich body-centered cubic Fe1.8B0.2 phase (~ 90%), coexisting with a minor α-Fe(P) solid solution (~ 10%). This constituent phase assembly forms far from equilibrium and highlights the role of sustained mechanical deformation in promoting partial metalloid incorporation into the iron lattice. As milling progresses, the microstructure undergoes continuous grain refinement together with a steady increase in defect density and internal strain. These changes play a key role in shaping the magnetic response, leading to soft magnetic behavior with low coercivity and stable permeability, governed by the competition between exchange interactions and defect-related pinning effects. Overall, the results highlight how mechanical milling can be used to stabilize metastable phases and tune structure–property relationships in Fe-B systems through controlled microstructural engineering.