A new（Fe0.76Si0.09B0.1P0.05）98.25Nb1Cu0.75 bulk nanocrystalline alloy in a rod shape with a diameter of 2.5 mm was successfully developed by copper mold casting and isothermal annealing. It was found that the introduction of Cu can result in the formation of a large number of α-Fe（Si）clusters（less than 3 nm） embedded in the glassy matrix, which greatly improved the primary crystallization of α-Fe（Si） nanocrystals during subsequent annealing. The obtained superior soft magnetic properties can be ascribed to the formation of optimal nanocomposite structures with a large number of α-Fe（Si） nanocrystals（ 17 nm） uniformly distributed in the glassy matrix.
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