While rare-earth magnets exhibit unchallenged hard-magnetic properties, looking for alternatives based on inexpensive elements of non-critical supply remains of utmost interest. Here, we demonstrate that (Fe,Co)₂(P,Si) single crystals combine a large magnetocrystalline anisotropy (K₁ ≈ 0.9 MJ m⁻³ at 300 K), high Curie temperatures (T_C up to 560 K) and an appreciable saturation specific magnetization (101 A m² kg⁻¹) leading to a theoretical |BH|_max ≈ 165 kJ m^-3, making them promising candidate materials as rare-earth-free permanent magnets. Our comparison between (Fe,Co)₂P and (Fe,Co)₂(P,Si) single crystals highlights that Si substitution reduces the low-temperature magnetocrystalline anisotropy, but strongly enhances T_C, making the latter quaternary alloys most favorable for room temperature applications. Submicron-sized particles of Fe_1.75Co_0.20P_0.75Si_0.25 were prepared by a top-down ball-milling approach. While the energy products of bonded particles are to this point modest, they demonstrate that permanent magnetic properties can be achieved in (Fe,Co)₂(P,Si) quaternary alloys. This work correlates the development of permanent magnetic properties to a control of the microstructure. It paves the way toward the realization of permanent magnetic properties in (Fe,Co)₂(P,Si) alloys made of economically competitive Fe, P and Si elements, making these materials desirable for applications.

We explore the crystal structure and magnetic properties of quaternary materials deriving from the hexagonal Fe₂P, an iron binary known to present a particularly large magnetocrystalline anisotropy potentially interesting for permanent magnets, but with unfortunately a Curie temperature far too low for applications. Using simultaneous metal and metalloid substitutions in Fe_2-zCo_zP_1-xB_x and Fe_2-zCo_zP_1-ySi_y quaternaries, we found it is possible to increase the Curie temperature up to at least 640 K while maintaining a c axis uniaxial magnetocrystalline anisotropy, leading to an appreciable magnetic anisotropy at room temperature. In Fe_2-zCo_zP_1-xB_x, though boron is appropriate to increase the Curie temperature, its amount is limited as it also favors the formation of secondary phases. Contrary to what could be anticipated from the phase diagrams of Fe_2-zCo_zP or Fe₂P_1-ySi_y ternaries, simultaneous Co for Fe and Si for P substitutions in Fe_2-zCo_zP_1-ySi_y are found to significantly expand the range of stability of the Fe₂P-type crystal structure. X-ray diffraction patterns on powders oriented in magnetic field indicate a c axis uniaxial magnetic anisotropy. Appropriate heat-treatments and slight metal deficiency are found suitable to limit the formation of unwanted secondary phase with 3:1 metal:metalloid ratio. As a result, nearly single-phase Fe_1.95-zCo_zP_1-ySi_y materials are prepared and exhibit an appreciable magnetic anisotropy with K₁ up to approximately 0.93 MJm⁻³ at room temperature. This study experimentally demonstrates that Fe₂P-type transition metal quaternaries can present an interest not only for their first-order magnetic transition, but also for their magnetic anisotropy making them potential candidates for magnetostatic applications.

An unconventional phenomena is observed at the first-order magnetic transitions in (Mn,Fe)₂(P,Si) materials. Here, we show that the first crossing of the transition upon cooling is associated with an abnormal temperature increase. While differential scanning calorimetry can detect this recalescence-like event, purposely-designed probes were employed to quantify it. Recalescence at a magnetic transition is extremely rare. But in (Mn,Fe)₂(P,Si), it is even more remarkable by its amplitude, with the temperature rising up to +4.0 K. In (Mn,Fe)₂(P,Si), this phenomenon is associated with irreversible burst-like evolution of the microstructure (increase in defect concentration and micro-cracking) and of the crystal structure.