Preparation of high performance sintered soft magnetic alloy by metal injection molding

High magnetic property Fe-50%Ni alloy was obtained by metal injection molding (MIM), hot isostatic pressing and subsequent heat treatment. The maximum permeability, saturation induction and coercive force are 112 mH m−1, 1.58 T and 2.52 A m−1, respectively. The maximum permeability far exceeds the reported value (22.36–42.50 mH m−1) of Fe-50%Ni produced by MIM. The relationships between processing parameters and density, microstructure and magnetic properties were investigated. The results revealed that magnetic performance was strongly influenced by density and microstructure.