Single-Step Synthesis of Nanocrystalline Fe-Ni/Fe-Co-Ni Magnetic Alloy Coating via Directional Plasma Spray

Fe-Ni-based nanocrystalline coatings with unique magnetic properties are widely used as soft magnetic materials and usually act as the core component in electronic devices. Nanocrystallized particles and thin films have become a popular contemporary research direction. Electrical explosion, characterized by an ultrafast atomization and quenching rate (dT/dt ~ 10⁹–10¹¹ K/s) for the material, is a unique approach for the rapid “single-step” synthesis of nanomaterials and coatings. In this study, experiments were carried out with intertwined wire under a directional spraying device in atmospheric Ar ambience. Two load systems of Fe-Ni and Fe-Ni-Co were considered in this work. Electrical parameters and high-speed camera images were obtained to reveal the physical mechanism and dynamic process of explosive spraying. The morphologic and crystallographic results were characterized by SEM and XRD. The magnetic properties were measured via VSM equipment, and the parameters of saturation magnetization M_s, residual magnetization M_r, and coercivity H_c were emphasized in the hysteresis loop pattern. The experimental results indicate that a dense coating was prepared with extremely low porosity, and the morphology of the coating surface shows different regions characterized by solidified chunks and loose particles. XRD patterns showed that crystalline structures were discrepant under two load systems with different Ni weight proportions. Magnetic measurements gave a thin and narrow hysteresis loop, which represents loops with good soft magnetic properties. Quantitatively, coercivity H_c decreased from 59.3 to 52.6 and from 121.0 to 49.9 for the coatings not containing and containing Co under parallel and perpendicular fields, respectively.