Accelerated Ordering of Cu Atoms and Synergistic Dual Anisotropy for Enhanced High‐Frequency Soft Magnetic Properties in Fe‐Based Alloys

ABSTRACT The inherent trade‐off between high saturation induction ( B s ) and low core loss in soft magnetic materials presents a challenge in the development of high‐frequency power electronics. Here, a processing approach that combines accelerated Cu ordering with dual magnetic anisotropy control in high‐ B s Fe‐based nanostructured cores is examined. This strategy results in a 26% in core loss, achieving 5.8 ± 0.1 W kg −1 at 0.2 T and 50 kHz, together with an 8% increase in B s . Microstructural characterization reveals that magnetic‐field‐driven accelerated Cu clustering promotes nanograin refinement, whereas the competition between reduced random anisotropy and weak uniaxial anisotropy optimizes domain wall behavior. These microstructural changes facilitate the formation of wide domain walls (108 ± 5 nm) and increase domain wall multiplication under high‐frequency excitation, thereby reducing hysteresis and excess loss. The combined strategy offers a feasible route for enhancing high‐frequency performance of high‐ B s materials, with potential application in compact and energy‐efficient power conversion systems.