Processing soft ferromagnetic glass-forming alloys through gas atomization and consolidation is the most effective technique to produce bulk samples. The commercial viability of these materials depends on commercial purity feedstock. However, crystallization in commercial purity feedstock is several orders of magnitude faster than in high purity materials. The production of amorphous powders with commercial purity requires high cooling rates, which can only be achieved by extending the common process window in conventional gas atomization. The development of novel cooling strategies during molten metal gas atomization on two model alloys ({(Fe_0.6Co_0.4)_0.75B_0.2Si_0.05}₉₆Nb₄ and Fe₇₆B₁₀Si₉P₅) is reported. Hydrogen inducement during liquid quenching significantly improved the glass-forming ability and soft magnetic properties of {(Fe_0.6Co_0.4)_0.75B_0.2Si_0.05}₉₆Nb₄ powders. Spark plasma sintering experiments verified that amorphous rings could be produced regardless of the cooling strategies used. While the saturation magnetization was almost unaffected by consolidation, the coercivity increased slightly and permeability decreased significantly. The magnetic properties of the final bulk samples were independent of feedstock quality. The developed cooling strategies provide a great opportunity for the commercialization of soft ferromagnetic glass-forming alloys with commercial purity.

通过气体雾化和固结处理软铁磁玻璃形成合金是生产大量样品的最有效技术。这些材料的商业可行性取决于商业纯度的原料。但是，商业纯度原料中的结晶比高纯度原料中的结晶快几个数量级。具有商业纯度的无定形粉末的生产需要高冷却速率，这只能通过扩展常规气体雾化中的通用工艺窗口来实现。在两种模型合金（{（Fe _0.6 Co _0.4）_0.75 B _0.2 Si _0.05 } ₉₆ Nb报道了Fe ₄ B ₄和Fe ₇₆ B ₁₀ Si ₉ P ₅。液相淬火过程中的氢诱导显着改善了{（Fe _0.6 Co _0.4）_0.75 B _0.2 Si _0.05 } ₉₆ Nb ₄的玻璃形成能力和软磁性能。粉末。火花等离子体烧结实验证明，不管使用何种冷却策略，都可以产生非晶环。尽管饱和磁化强度几乎不受固结的影响，但矫顽力略有增加，而导磁率却明显下降。最终散装样品的磁性能与原料质量无关。发达的冷却策略为商业纯度的软铁磁玻璃形成合金的商业化提供了巨大的机会。