Microstructure Heredity and Phase Transformation of CoFeB Pre-Alloyed Powder During Hot Pressing Sintering

The Co40Fe40B20 alloy is a key magnetic material that combines high saturation magnetization with excellent soft magnetic properties, offering broad application prospects in fields such as spintronic devices, magnetic tunnel junctions, and tunnel magnetoresistive sensors. Hot pressing can be used to produce fine-grained, highly dense CoFeB alloys. However, there is currently a lack of systematic research on the intrinsic mechanisms by which the particle size of gas-atomized CoFeB powders and their non-equilibrium solidification microstructure regulate phase transformations, microstructural evolution, and densification behavior during hot pressing and sintering—particularly regarding the microstructural inheritance effects of powders with different particle sizes. To address this issue, this study used vacuum induction melting and gas atomization technology to prepare Co40Fe40B20 pre-alloyed powders in three particle size ranges: <38 μm, 38–74 μm, and 74–154 μm. Under identical process parameters, corresponding bulk alloys were produced via vacuum hot-press sintering, and the effects of initial powder particle size on phase transformations and microstructural evolution in the sintered bodies were systematically investigated. Microstructural characterization revealed the complete phase evolution of the alloy from the non-equilibrium solidified powder state to the sintered equilibrium state. During hot-press sintering, the metastable (Fe,Co)3B phase in the powder completely decomposed, transforming into a stable body-centered cubic bcc-(Fe,Co) phase and a bcc-(Fe,Co)2B second phase. The dispersed (Fe,Co)2B phase precipitated after sintering strongly inhibits grain boundary migration via the Zener pinning effect, effectively hindering grain growth and resulting in a uniform, fine-grained, equiaxed microstructure. In coarse powders, due to the presence of a portion of the (Fe,Co)2B phase, this phase aggregates and grows during sintering, weakening the pinning effect and leading to abnormal grain growth. The Hall–Petch fine-grain strengthening effect resulting from grain refinement couples with and offsets the weakening of second-phase strengthening caused by second-phase coarsening, ultimately leading to sintered bodies prepared from powders of different particle sizes exhibiting similar macroscopic density and hardness properties.