Abstract: The investigating of Co-based amorphous alloys and their optimal annealing process which is applicable to leakage current sensors is of great significance for improving the accuracy of sensors. Based on three kinds of commercial Co-based amorphous alloys, this work systematically investigates the effects of alloy composition and two-stage annealing on their magnetic properties, inductance characteristics, and comprehensive performance of the corresponding sensors. It is found that by simultaneous stress relief and longitudinal magnetic field annealing, the internal stress in Co-based amorphous alloys can be effectively eliminated, the regular orientation of magnetic domains is adjusted, and the pinning defects in magnetic domains are eliminated, which therefore decrease the coercivity and achieve a substantial attenuation of inductance under micro-currents while increasing initial inductance. The Co67Fe4Mo1.5Si16.5B11 amorphous alloy has been successfully prepared with excellent soft magnetic properties of a saturation magnetic flux density of 0.55 T, low coercivity of 0.16 A/m, and high effective permeability of 35 200. The lea-kage current sensor made thereof exhibits a high accuracy of 0.50%, low nonlinear error of 0.16%, low zero temperature drift coefficient of 29.18 ppm/℃, respectively, as well as high frequency bandwidth of 18 kHz and low noise of 0.77 mV. The intrinsic interaction between sensor performance and magnetic properties, magnetic anisotropy has been established, which reveals that the saturation magnetic flux density is the most important parameter that determines the linearity of the leakage current sensor. The lower the saturation magnetic flux density, the more rapid the attenuation of inductance under micro-currents, and the smaller the linearity, and the higher the accuracy of the sensor. Meanwhile, a lower coercivity and a higher effective permeability, which result from the smaller induced anisotropy, are not only advantageous to increasing the initial inductance of the sensor, but also to enhancing its sensitivity and reducing the nonlinear error. The findings provide theoretical guidance and material support for developing leakage current sensors with high accuracy.
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2026, Vol. 40 
