The crystallization kinetics of [(Fe_0.5Co_0.5)_0.75B_0.2Si_0.05]₉₆Nb₄ and {[(Fe_0.5Co_0.5)_0.75B_0.2Si_0.05]_0.96Nb_0.04}_99.5Cu_0.5 bulk metallic glasses were evaluated using differential scanning calorimetry under non-isothermal condition. The fully glassy rods with diameters up to 2 mm were obtained by copper mold injection casting. Both glasses show good thermal stability, but the addition of only 0.5% Cu completely changes the crystallization behavior. The average activation energy required for crystallization decreases from 645 kJ/mol to 425 kJ/mol after Cu addition. Upon heating, the Cu-free alloy forms only the metastable Fe₂₃B₆ phase. In contrast, two well-separated exothermic events are observed for the Cu-added bulk glassy samples. First, the (Fe,Co) phase nucleates and then (Fe,Co)₂B and/or (Fe,Co)₃B crystallize from the remaining glassy matrix. The Cu-added alloy exhibits a lower coercivity and a higher magnetic saturation than the base alloy, both in as-cast as well as in annealed condition. Besides, the Cu-added glassy sample with 2 mm diameter exhibits a maximum compressive fracture strength of 3913 MPa together with a plastic strain of 0.6%, which is highest plastic strain ever reported for 2 mm diameter ferromagnetic bulk metallic glass sample. Although Cu addition improves the magnetic and mechanical properties of the glass, it affects the glass-forming ability of the base alloy.

Soft ferromagnetic Fe-based bulk metallic glass key-shaped specimens with a maximum and minimum width of 25.4 and 5 mm, respectively, were successfully produced using a high pressure die casting (HPDC) method, The influence of die material, alloy temperature and flow rate on the microstructure, thermal stability and soft ferromagnetic properties has been studied. The results suggest that a steel die in which the molten metal flows at low rate and high temperature can be used to produce completely glassy samples. This can be attributed to the laminar filling of the mold and to a lower heat transfer coefficient, which avoids the skin effect in the steel mold. In addition, magnetic measurements reveal that the amorphous structure of the material is maintained throughout the key-shaped samples. Although it is difficult to control the flow and cooling rate of the molten metal in the corners of the key due to different cross sections, this can be overcome by proper tool geometry. The present results confirm that HPDC is a suitable method for the casting of Fe-based bulk glassy alloys even with complex geometries for a broad range of applications.