Ta-inserted SmCo5/Fe nanocomposite thick film magnets were synthesized by high-speed pulsed laser deposition followed by pulse annealing. The microstructures of the film magnets were characterized by high-resolution scanning electron microscopy and scanning transmission electron microscopy. The as-deposited thick film possessed a multilayered Sm-Co/Ta/α-Fe/Ta structure with amorphous Sm-Co layers and -oriented crystalline α-Fe layers. After pulse annealing, many fine grains of Laves phase TaCo2 were formed, and then the multilayered structure was converted to a granular nanocomposite thick film magnet composed of fine crystalline grains of Sm(Co, Fe)5, α-(Fe, Co), and TaCo2. The volume fractions and grain sizes of hard magnetic Sm(Co, Fe)5, soft magnetic α-(Fe, Co), and TaCo2 were controlled by the thicknesses of the Ta layer, producing a nanocomposite thick film magnet with good exchange coupling.
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