Fe-Ni based alloys as rare-earth free gap permanent magnets

L10-ordered FeNi phase has potential as a rare-earth free permanent magnet due to its large magnetization and high Curie temperature. However, low long-range crystal ordering and weak magnetocrystalline anisotropy (Ku) impede its practical use in a technologically relevant permanent magnet. Employing density functional and Monte Carlo simulations, we demonstrate the substantial improvements on structural and thermal stability, disorder-order phase transition, and intrinsic permanent magnetic properties of Fe-Ni structures. We propose that this is achievable through the complementary elemental substitutions by metal elements (M) and interstitial doping with 2p elements. Fe1-xMxNi with simple metal (M = Ga and Al) and metalloid (M = Ge and Si) elemental substitutions at x = 0.5 are broadly known as Heusler (L21) structures with no permanent magnet characteristics. On the contrary, we find that for x = 0-0.5, L10-type structure is energetically favored over the Heusler-type structures. The predicted structures exhibit Ku values up to approximately 2.1 MJ/m3, which is roughly three times that of FeNi phase (0.68 MJ/m3), where the absolute value of Ku depends on the degree of L10 crystal ordering. Interstitial doping with B elevates Ku further up to a maximum value of 3.9 MJ/m3 (at 0 K), leading to room-temperature intrinsic permanent magnetic properties, including maximum energy density product (BH)max, anisotropy field mu 0Ha, and hardness parameter kappa, comparable to the widely investigated MnBi and MnAl permanent magnets. These results may serve as a guideline in designing Fe-Ni based rare-earth free gap permanent magnetic materials that were previously overlooked.