Abstract: Fe-6.5% Si electrical steel is alloyed with boron to reduce its melting temperature and interfacial energy to improve processability for melt-spinning applications. Boron additions from 0.01 wt % to 2.24 wt % into Fe-6.5% Si and its effect on ribbon thickness, grain size, magnetic, and mechanical properties are disclosed. Minor boron alloying significantly changed the melt pool stability and wetting on a melt-spinning quench wheel and in turn increased the quench rate with minimum impact on the magnetic saturation and ductility. Boron addition of less than 0.06 wt % was also found beneficial to the magnetic property of the alloy by lowering both its hysteresis and eddy current losses.