Magnetostrictive Fe–Ga wires 1–3 mm in diameter have been prepared using an innovative cost-effective approach—based on the Taylor wire method—that couples the advantages of high-temperature directional solidification and selective grain growth. Strict control of drawing processes has been shown to enable the introduction of desirable texture that is critical for achieving large magnetostriction in these polycrystalline Fe–Ga alloys. The procedure for fabricating highly textured ⟨1 0 0⟩ magnetostrictive wires is discussed and the wires are evaluated in terms of microstructure and crystallographic texture. Magnetostriction measurements, in the absence of pre-stress and stress-annealing treatments, indicated a maximum magnetostriction of ∼170 ppm in a saturation field less than 60 mT. A mechanism for texture evolution is proposed. It is speculated that the resultant ⟨1 0 0⟩ texture of the Fe–Ga wires is due to directional solidification and abnormal grain growth resulting from surface effects. The unique properties of wires made with the Taylor-based approach coupled with the low fabrication cost make this an attractive approach for the production of Fe–Ga wire with a specific crystallographic texture.

Recently, low-cost processing approaches that produce textured thin bodies have engendered interest as cost-effective approaches for fabrication of magnetostrictive Fe-Ga alloys. In particular, wire-forming methods that strictly control the solidification direction could lead to some measure of crystallographic texture control. This is critical for development of large magnetostriction in polycrystals and for use of the alloys in actuators, sensors, energy harvesters and other systems. Magnetostrictive Fe-Ga wires have been prepared using an innovative costeffective approach -based on the Taylor wire method -that combines rapid solidification and deformation processes. The procedure for making magnetostrictive wires is discussed and the wires are evaluated in terms of microstructure, crystallographic texture and magnetostriction. Results show that the Taylor-based approach is an effective and versatile means to draw 1-3 mm diameter textured Fe-Ga wire. Experimentation on the influence of drawing technique and quench conditions on texture development resulted with production of a strong <100> fiber texture in the Fe-Ga wire. Magnetostriction measurements, in the absence of prestress, indicated a maximum magnetostriction of ~165 ppm in a saturation field of less than 200 mTesla. This is considered a significant strain for bulk polycrystalline Fe-Ga alloys without a pre-stress or a stress-annealing treatment. The unique properties of wires made with the Taylor-based approach coupled with the low intrinsic cost make this an attractive approach for production of textured magnetostrictive wire for a variety of applications.