Flexible amorphous alloy circuits

Bend, Don't Break: How New Alloys are Revolutionizing Electronics

Samir D’Costa in Tech & Innovation September 2025 • 4 min read.

"Scientists develop novel Fe-Co-B-P-C amorphous alloys, unlocking enhanced flexibility and magnetic potential for next-gen devices."

Imagine a world where your electronic devices are virtually indestructible, capable of bending and flexing without compromising performance. This vision is edging closer to reality thanks to the innovative research into a unique class of materials known as amorphous alloys, specifically Fe-based alloys. These materials are poised to revolutionize industries, from high-speed electromotors to magnetic stress sensors.

Traditional soft magnetic materials, such as ferrite, silicon steel, and permalloy, have limitations. While they possess essential magnetic properties, they often fall short in terms of saturated magnetization, effective permeability, coercivity, and core loss—especially at higher frequencies. Fe-based amorphous alloys, with their unique structure and excellent magnetic and mechanical properties, offer a compelling alternative.

A recent study has focused on a novel composition of Fe-Co-B-P-C amorphous alloys, demonstrating a breakthrough in achieving both high saturated magnetization (up to 1.79 T) and exceptional bending ductility. This discovery addresses a critical need for materials that can withstand significant stress and deformation without losing their magnetic capabilities, opening up new possibilities for device design and functionality.

What Makes These Alloys So Special?

The creation of Fe-Co-B-P-C amorphous alloys involves carefully manipulating their composition to achieve a non-crystalline, or amorphous, structure. This is typically done through rapid solidification techniques, like melt spinning, where the molten alloy is cooled extremely quickly. The resulting material lacks the long-range atomic order found in crystalline metals, giving rise to unique properties.

The specific combination of elements in Fe-Co-B-P-C alloys is crucial for achieving the desired characteristics. Iron (Fe) provides the base magnetic properties, while cobalt (Co) enhances the saturation magnetization. Boron (B), phosphorus (P), and carbon (C) act as glass formers, promoting the formation of the amorphous structure and improving thermal stability.

Here's a closer look at the key features:

High Saturated Magnetization: The presence of cobalt allows these alloys to achieve magnetization levels up to 1.79 T, making them suitable for applications requiring strong magnetic fields.
Excellent Bending Ductility: These alloys can withstand significant bending without fracturing, even after being annealed at high temperatures. This flexibility is crucial for applications where the material needs to conform to complex shapes or endure mechanical stress.
Tunable Magnetic Properties: By adjusting the alloy composition and applying tensile stress, the magnetic properties, such as coercivity, can be precisely controlled. This tunability allows for optimization for specific applications.

The study further explored the impact of substituting cobalt for iron in the alloy composition. Researchers found that increasing the cobalt content significantly improved the saturated magnetization and Curie temperature (the temperature above which a material loses its ferromagnetism). However, it also led to an increase in coercivity, which is a measure of the material's resistance to demagnetization. To counter this, the researchers investigated the application of tensile stress, discovering that it could effectively reduce coercivity and enhance the alloy's soft magnetic properties.

The Future of Flexible Electronics

The development of Fe-Co-B-P-C amorphous alloys represents a significant step forward in materials science, paving the way for more durable, efficient, and versatile electronic devices. With their unique combination of high saturated magnetization, excellent bending ductility, and tunable magnetic properties, these alloys hold immense potential for a wide range of applications, from high-speed electromotors to magnetic stress sensors and beyond.

About this Article -

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This article is based on research published under:

DOI-LINK: 10.1016/j.jallcom.2018.11.147, Alternate LINK

Title: Tunable Magnetic Properties And Heat-Treatable Bending Ductility Of Fe-Co-B-P-C Amorphous Alloys With A High Saturated Magnetization Up To 1.79 T

Subject: Materials Chemistry

Journal: Journal of Alloys and Compounds

Publisher: Elsevier BV

Authors: Zhiguang Shi, Ran Li, Tao Zhang

Published: 2019-03-01

Everything You Need To Know

What makes Fe-Co-B-P-C amorphous alloys so special compared to traditional soft magnetic materials?

Fe-Co-B-P-C amorphous alloys stand out due to their unique combination of high saturated magnetization (up to 1.79 T) and exceptional bending ductility. This means they can withstand significant bending without breaking and maintain strong magnetic properties. The ability to tune their magnetic properties by adjusting the alloy composition and applying tensile stress further enhances their versatility. These characteristics differentiate them from traditional soft magnetic materials like ferrite, silicon steel, and permalloy, which often have limitations in terms of saturated magnetization, effective permeability, coercivity, and core loss, particularly at higher frequencies.

What role does each element (Fe, Co, B, P, C) play in determining the properties of Fe-Co-B-P-C amorphous alloys?

The specific elements in Fe-Co-B-P-C amorphous alloys contribute distinct properties. Iron (Fe) provides the base magnetic properties. Cobalt (Co) enhances the saturation magnetization. Boron (B), phosphorus (P), and carbon (C) act as glass formers, promoting the formation of the amorphous structure and improving thermal stability. The careful balance of these elements is essential to achieve the desired combination of magnetic and mechanical properties.

What impact does increasing the cobalt content have on the magnetic properties of Fe-Co-B-P-C amorphous alloys, and how can the negative effects be mitigated?

Researchers discovered that increasing the cobalt content in Fe-Co-B-P-C amorphous alloys improves the saturated magnetization and Curie temperature. However, it also increases coercivity, which is a measure of the material's resistance to demagnetization. To counter this, they applied tensile stress, which effectively reduced coercivity and enhanced the alloy's soft magnetic properties. This highlights the importance of composition control and post-processing techniques in tailoring the magnetic properties of these alloys.

How are Fe-Co-B-P-C amorphous alloys manufactured, and why is the manufacturing process important?

Fe-Co-B-P-C amorphous alloys are created using rapid solidification techniques, such as melt spinning. In this process, the molten alloy is cooled extremely quickly. This rapid cooling prevents the formation of a crystalline structure, resulting in an amorphous structure where atoms are arranged randomly. This amorphous structure gives rise to the unique mechanical and magnetic properties of these alloys.

What are some potential applications for Fe-Co-B-P-C amorphous alloys, and what makes them suitable for these applications?

Fe-Co-B-P-C amorphous alloys show promise for use in a variety of applications, including high-speed electromotors, magnetic stress sensors, and more durable electronic components. Their high saturated magnetization and tunable magnetic properties make them ideal for applications requiring strong and controllable magnetic fields. Their bending ductility makes them suitable for devices that need to withstand mechanical stress or conform to complex shapes. The full extent of their potential applications is still being explored, with ongoing research and development efforts focused on optimizing their properties and exploring new uses.