Fe–Si alloys are an essential class of soft magnetic materials due to their high magnetic permeability and low hysteresis loss. Increasing the Si content above 3 wt% promotes coarser grain sizes and greater electrical resistivity, thereby enhancing the magnetic properties, such as magnetic permeability and specific loss density. However, the increased silicon content makes the machining challenging. Additive manufacturing technologies enable production of near net shape Fe–Si alloys with high silicon content, practically eliminating the machining challenges. This work investigated the effects of Si content, which ranged from 3 to 5 wt%, and B content, which ranged from 0 to 0.25 wt%, on the microstructure and magnetic properties. The Fe–Si–B alloys were binder jet printed, where the sintering temperature was varied between 1200 and 1250 °C, and microstructure-magnetic property relationships were investigated by characterizing the magnetic permeability, intrinsic coercivity, grain size, and density. The Fe-5wt.%Si alloy with 0.25% B sintered at 1200 °C exhibited the highest magnetic relative permeability (4447) and the lowest intrinsic coercivity (47.8 A/m).

Fe-Si合金由于具有高磁导率和低磁滞损耗，是一类重要的软磁材料。将 Si 含量增加到 3 wt% 以上会促进更粗的晶粒尺寸和更大的电阻率，从而提高磁性能，例如磁导率和比损耗密度。然而，增加的硅含量使加工具有挑战性。增材制造技术能够生产具有高硅含量的近净形 Fe-Si 合金，实际上消除了加工挑战。这项工作研究了 Si 含量（范围为 3 至 5 wt%）和 B 含量（范围为 0 至 0.25 wt%）对微观结构和磁性能的影响。Fe-Si-B 合金采用粘合剂喷射印刷，烧结温度在 1200 至 1250 °C 之间变化，通过表征磁导率、内禀矫顽力、晶粒尺寸和密度，研究了微观结构与磁性能之间的关系。在 1200 °C 下烧结的含 0.25% B 的 Fe-5wt.%Si 合金表现出最高的相对磁导率 (4447) 和最低的内禀矫顽力 (47.8 A/m)。