Magnetostrictive thin-film coated Surface Acoustic Wave (SAW) devices were promising for sensing magnetic field owing to their superior features as micro-size, fast response, and high sensitivity originated from the magnetostrictive effect. However, the magnetostriction nature in magnetostrictive thinfilm causes significantly mechanical fatigue in service, deteriorating the sensor performances. In this work, the fatigue phenomenon in magnetostrictive coating was underlined by characterizing the prepared FeCo thin-film coated magnetic device cyclically. Obvious shedding was observed in FeCo coating after cyclic testing and the magnetic-sensitivity decreases significantly. One of the reasons is the weak adhesion of FeCo thin-film towards the substrate. As an available way allowing enhancement of adhesion, a Cr thinfilm was employed as the transition-layer to weaken the mechanical fatigue. However, it accompanied by the issue of the reduced magnetostrictive coefficient and the obstruction in magnetostrain-tranfer to piezoelectric substrate. As a result, the slump in sensitivity was observed. To address such issues, a design of dotted-pattern with Cr transition layer was employed to build the SAW based magnetic-device. High magnetic-sensitivity and excellent long-term stability were achieved because of the release of coercive force in FeCo dots and enhancement of the FeCo adhesion to the substrate.INDEX TERMS Dotted-pattern, mechanical fatigue, magnetostrictive effect, SAW magnetic sensor, Cr transition layer.