Abstract Nanocrystalline flakes of FeSiAlCr were synthesized by atomization process and high energy ball milling. Effect of process conditions on microstructure, morphology and microwave electromagnetic characteristics of FeSiAlCr particles were investigated. Results show that flaky morphology and nanocrystalline microstructure were gained by process of high energy ball milling. Thus, microwave permeability were improved remarkably and permittivity were controlled effectively. Effect of sequent annealing was also discussed and it was found that microwave electromagnetic performances were improved further. Microwave absorbing ability of coating layer made of the nanocrystalline FeSiAlCr flakes proved that the materials can be applied in suppression of electromagnetic interference or microwave absorption.
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