Diffusion of Nd-rich phase in the spark plasma sintered and hot deformed nanocrystalline NdFeB magnets

The role of the Nd-rich phase in developing microstructure and properties of isotropic and anisotropic NdFeB magnets has been investigated. Melt spun Nd-rich Nd13.5Fe73.5Co6.7Ga0.5B5.6 and Fe-rich Nd7.7Pr2.6Fe84.1B5.5 alloy powders were mechanically mixed with different ratios. The mixed powders were consolidated into isotropic magnets and anisotropic magnets by spark plasma sintering (SPS) and SPS followed by hot deformation, respectively. The composition and microstructure of diffusion area between Nd-rich and Fe-rich compositions for isotropic and anisotropic magnets were investigated. The gradient distribution of Nd content from Nd-rich to Fe-rich area due to the diffusion of liquid Nd-rich phase in the SPS and hot deformation was observed, which leads to gradually changes in grain structure. The remanent polarization of 1.29 T, coercivity of 995 kA/m, and maximum energy product of 293 kJ/m³ are obtained for an anisotropic magnet. The role of the Nd-rich phase has to be carefully considered in order to achieve deformation anisotropy and fine grains in the NdFeB magnets.