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The thermal stability of milling Fe86Zr11-xNbxB3 (x = 5.5, 6) melt-spun strip powders and the influence of high-pressure sintering conditions on phase component and grain size of bulk alloys were investigated by X-ray diffractometry (XRD), differential scanning calorimetry (DSC) and scanning electron microscopy (SEM). The results show that milling melt-spun powder remains in the amorphous state, and the crystallization temperature of which is 480-530°C, the apparent activation energy Ep of crystallization process is 294.1-219.5 kJ/mol. The increasing Nb content can increase crystallization temperature and decrease Ep. Under the sintering conditions of 5.5 GPa/3 min, when Pw is 1150 W, single phase α-Fe nanocrystalline (20.6-26.7 nm) bulk alloy with relative density higher than 99.0% can be obtained. Under the sintering conditions of 5.5 GPa/1150 W/3 min, the magnetic properties of these nanocrystalline bulk alloys are Fe86Zr5.5Nb5.5B3 alloy, Bs = 1.15 T, Hc = 5.08 kA·m-1; Fe86Zr5Nb6B3 alloy, Bs = 1.26 T, Hc = 4.27 kA·m-1.
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