The effects of process parameters for the in-rotating-water quenching technique have been investigated with respect to structural, magnetic and giant magneto-impedance (GMI) properties of FeCoSiB alloy microwires. Continuous and ductile amorphous wires have been found with the optimization of process parameters. The structural, magnetic and GMI behaviors have been evaluated as a function of wire diameter. The crystallinity of the wires increases with wire diameter, affecting soft magnetic and GMI properties. Consequently, it is found that the wire of 110 μm diameter shows superior soft magnetic and GMI properties. © 2012 Springer-Verlag.