Effect of In doping on the evolution of microstructure,magnetic properties and corrosion resistance of NdFeB magnets

The grain boundary phase affects the magnetic properties and corrosion resistance of sintered NdFeB magnets.In this work,a small amount of In was added to NdFeB magnets by induction melting to systematically investigate its effect on the evolution of the microstructure,magnetic properties and corrosion resistance of NdFeB magnets.Microstructural analysis illustrated that minor In addition generated more grain boundary phases and an abundant amorphous phase at the triple-junction grain boundary.While the addition of In failed to enhance the magnetic isolation effect between adjacent matrix grains,its incorporation fortuitously elevated the electrochemical potential of the In-containing magnets.Besides,during corrosion,an In-rich precipitate phase formed,hindering the ingress of the corrosive medium into the magnet.Consequently,this significantly bolstered the corrosion resistance of the sintered NdFeB magnets.The phase formation,magnetic properties and corrosion resistance of In-doped NdFeB magnets are detailed in this work,which provides new prospects for the preparation of high-performance sintered NdFeB magnets.

Microstructure and corrosion resistance of sintered NdFeB magnet modified by intergranular additions of MgO and ZnO

Microstructure and corrosion resistance of sintered Nd15Dy1.2Fe77Al0.8B6 and Nd22Fe71B7 magnets modified by intergranular addition of MgO and ZnO were investigated. Both the remanence and sintering density of the magnets increased slightly with intergranular additions of MgO and ZnO. There was a remarkable increase in coercivity of Nd22Fe71B7 after addition. Besides, the effects on magnetic properties and an improved corrosion resistance were observed. Compared with the native magnets without addition, corrosion potential of the magnets with MgO and ZnO additives was more positive and the current density in the anodic branch of the polarization curve was reduced. Corrosion resistance resulting from autoclave testing （2×10^5 Pa of steam pressure, 120 ℃） showed that the corrosion rate of NdFeB magnets reduced with the increase of additive amount. Microstructure observation revealed that MgO and ZnO additives were incorporated into the intergranular phases in the magnets. With the introduction of MgO and ZnO, more intergranular phase with high oxygen content was formed while keeping the volume fraction of all the intergranular phases almost unchanged, which may contribute to improved corrosion resistance. Furthermore, addition of MgO and ZnO refined the grain size of Nd22Fe71B7.

Multilayer ceramic coating for impeding corrosion of sintered NdFeB magnets

Sintered NdFeB magnets have complex microstructure that makes them susceptible to corrosion in active environments.The current paper evaluated the anticorrosion characteristics of multilayer titanium nitride ceramic coating applied through cathodic arc physical vapour deposition(CAPVD) for protection of sintered NdFeB permanent magnets.The performance of ceramic coating was compared to the electrodeposited nickel coating having a copper interlayer.Electrochemical impedance spectroscopy(EIS) and cyclic polar...

Influence of Solidiflcation Rate on Microstructures of Cast Strips and Corresponding Sintered NdFeB Magnets

The influences of solidification rate on the microstructures of cast strips and corresponding sintered NdFeB magnets were investigated. The experimental results show that the volume fraction and size of columnar grains vary with the wheel speed V, and the fraction is highest to more than 90% with 3.5μm in average width at V = 2m·s-1. The reasons for the improved magnetic performance were discussed based on the micromagnetic theory and microstructure analyses of the strips and sintered magnets. The magnetic properties of sintered NdFeB magnets made from the (Nd,Dy)13.0(Fe,Ga, Al)80.5B6.5 cast strip which was obtained at V = 2 m·s-1 are as follows: Br = 1.15 T( 11.25 kG), iHc = 2799 kA·m-1 (35.2 kOe) and (BH)max = 242 kJ·m-3(30.35 MGOe).

Anisotropic NdFeB Magnet Fabricated by Single Stroke Hot Deformation

The general hot deformation process consists of two steps, hot pressing and die-upsetting in order to obtain the anisotropic NdFeB magnet. This is the first report that the high anisotropy NdFeB magnets can be fabricated by single stroke hot deforming the isotropic magnet. The magnetic properties of those materials are: coercivity iHc ～11 kOe, remanence Br ～12 kG, and the maximum energy product (BH)max ～28 MG.Oe.

High Energy and High Coercivity Sintered NdFeB Magnets by Low Oxygen Process

Using ball milling and single direction pressing, we can produce high performance NdFeB sintered magnets. The oxygen content of sintered magnets can be controlled under 1500xl0^-6 and the magnetic performance can be improved by using low oxygen processing. The high preformance NdFeB sintered magnets with Br=(1.4 ± 0.2)T, iHc>796 kA/m and (BH)max=(390± 16) kJ/m^3, have been batch produced.

MICROSTRUCTURE AND MAGNETIC HARDENING OF SINTERED NdFeB MAGNETS DOPPED WIHT Dy OR Dy_2O_3

The magnetic properties,microstructure and magnetic hardening of sintered (Nd_(1-x)Dy_x)_(16)Fe_(77.2)B_(6.8) and Nd_(16)Fe_(77.2)B_(6.8)+ywt-%Dy_2O_3 magnets have been stud- ied.As an addition of Dy to the magnet during smelting,Dy atoms may enter the matrix phase Nd_2Fe_(14)B,so as to enhance H_A,refine grains and improve boundary struc- ture,as well as to increase H_(ci)of the magnet.If Dy_2O_3 is added to powder material prior to sintering,Dy atoms diffuse into the epitaxial layer of grains of matrix phase causing enhancement of K′_1,also refinement of grains and improvement of boundary structure.The NdFeB based permanent magnets with higher H_(ci) and greater(BH)_m may be produced by adding about 2—3 wt-% Dy_2O_3 which make a favourable condition for lower cost.

BOUNDARY MICROSTRUCTURE AND MAGNETIC HARDENING OF SINTERED NdFeB MAGNET

The boundary microstructure of sintered alloy Nd_(15.5)Fe_(77)B_-(7.5) has been studied by TEM,AES and SAED.The boundary structure may be distinguished into 4 types.The first three types remain the same during annealing,and the fourth changes its microstructure remarkably.The 4th type is composed of two different regions,i.e.,the central Nd-rich phase and the epitaxial laver of the Nd_2Fe_(14)B grains.Owing to the atomic diffusion and other types of mass trans- port,magnetic hardening occurred in the epitaxial layer,thus the coercivity of the alloy has been improved.

Further Development of NdFeB Magnet Industry in China

Due to continued growth in key markets a broadening of application base and performance improvements, the market demands of NdFeB magnet increased steadily in 1998, and the global output of sintered NdFeB magnet exceeded 10,000 t, in spite of the economic recession in Asia. In 1998 China produced 3,850 t sintered NdFeB block magnet, with an annual growth rate of +22% over the output in 1997.

Experimental and Numerical Analysis of Surface Magneto-Hydrodynamic Propulsion Induced by NdFeB Magnets

The so-called surface Magneto-hydro-dynamic(MHD)propulsion relies on the Lorentz force induced in weak electrolyte solutions(such as seawater or plasma)by NdFeB Magnets.The Lorentz force plays an important role in such dynamics as it directly affects the structures of flow boundary layers.Previous studies have mainly focused on the development of such boundary layers and related fluid-dynamic aspects.The main focus of the present study is the determination of electromagnetic field distributions around the propulsion units.In particular dedicated experiments and numerical simulations(based on the finite volume method)are conducted considering a NACA0012 airfoil immersed in seawater.The results show that,along the propulsion unit,the field strength undergoes a rapid attenuation in the direction perpendicular to the wall.

China's First Joint Venture Making NdFeB Magnets——Beijing Century New Magnets Co. Ltd

AFast quenching NdFeB permanent magnet—a high-tech product filling in the domestic gaps—has been put into mass production by the Beijing Century New Magnetics Co. Ltd. Previously, only the United States of America had patent rights for production and sale of fast quenching NdFeB Magnets, and only General Motor Company could produce such high-tech products.

Development of NdFeB Magnet Industry in New Century (Continued)

Europe was the gLobaL magnets center before World War Ⅱ. Afterwards, it had shifted to USA. Till Late 1960s, the center had moved to Japan. EventuaLLy, it moved to China at the beginning of 21st century. Magnet output in different countries （2005） is shown in Table 3.

Development of NdFeB Magnet Industry in New Century (Continued)

1.2.2 Output decline at the beginning of the new century Output of sintered NdFeB magnets during 1993 to 2005 was characterized by three features: turning point in 2001; completely ceased production in USA by the end of 2003, very small production volume in Europe in those years and the recovered output in Japan since 2002; sharply increased output in China since 2002. Today, almost 80% of global total output is concentrated in China. The year 2001 was a "nightmare" for global magnet industry. Main consumers of NdFeB magnets - IT and computer industries greatly reduced their purchase of magnets due to the global economic recession. Statistics showed that the output of sintered NdFeB magnets in Japan in 2001 was 20.3% fallen in comparison with that in 2000 and the sales value was dropped by 36.2%. The similar situation happened to USA and Europe, with their outputs dropped by 40% and 15% respectively, and their sales value dropped by 51% and 34.9% each. Since then, the production in USA and Europe was decreased continuously. China was the only exception in the world escaped from the downward tendency. The turning point of global production of magnets appeared in 2001 due to the sharp output reduction of sintered NdFeB in the West.

2004 CHINESE NdFeB MAGNETS

Chinese RE magnetic materials develop quickly in recent years. It is estimated that the output of NdFeB magnetic materials exceeded 23,000 tons, occupying over 60% of world market, in 2004. Chinese NdFeB industry demonstrated the following characteristics:

Effect of Annealing on the Magnetism of the Sintered NdFeB Magnet

This paper deals with the effect of annealing on the magnetism of the sintered NdFeB magnet with a composi- tion of Nd3oB5M Alo.6Nbo.7Feft2.4- Microstructural investigations of the grain size and grain boundaries with SEM were carried out. Microstructural investigations showed the presence of some Nd-rich phase in grain boundaries and main phase. The results of magnetic properties analysis shows that this non-magnetic Nd-rich phase, produced in annealing process, can increase or decrease the magnetism of the sintered NdFeB-type permanent magnet. Appropriate amount of Nd-rich phase will strengthen the pinning field and elevated the coercive force of magnet, but too many these non-magnetism phases in Nd2Fei4B main phase will decrease it. When the sintered NdFeB magnet was annealed at 3Pa and 492°C for an hour the coercive force would raise from 915.6kA/m to 1164.8kA/m, and the (BH^ from 277.7kJ/m to 349.5kJ/m. How- ever, annealing at a non-optimized temperature at 542 °C, microstructure changes in some main phase will leading the de- crease of properties.

Characterization of Microstructure and Magnetic Properties of NdFeB Magnet with Dy, Al and Cu Additions

A new alloy of Nd33.5Dy0.99Febal.Al0.52Cu0.1B1.15 (%, mass fraction) was fabricated by powder metallurgy. The effects of Dy, Al and Cu additions on the microstructure and magnetic properties of sintered NdFeB magnet were investigated. The additions of Dy, Al and Cu are effective to refine grains and improve coercivity. Moreover, suitable amounts of Dy, Al and Cu lead to a demagnetization curve with good rectangularity. It is found that the sintered NdFeB magnet has relatively high magnetic performance of Br=12.17 kGs, jHc=13.52 kOe and (BH)max=34.71 MGOe. The sintered NdFeB sample was examined by magnetic force microscope which revealed the domain structures at the surface. It is revealed that the mean Nd2Fe14B grain size is significantly larger than the average scale of the magnetic contrast. An explanation about this is that most Nd2Fe14B grains in sintered NdFeB alloy are dominated with the multidomain structures when the magnet is in thermally demagnetization state.

A Study of Grain Growth Kinetics in Sintered NdFeB Magnets

The Nd2Fe14 B grain growth kinetics in sintered NdFeB magnets with nominal compositions of Nd30+xDy1.5Fe67.08-xAl0.4B1.02 (%, x = 0, 3) was studied. The grain size parameters were determined by means of the linear intercept method on SEM secondary electron images. It is observed that the grain growth process is more sensitive to sintering temperature than to sintering time although the grain size rises with both sintering temperature and time. It is also found that magnets prepared from the pre-alloy powder with a higher oxygen content exhibit a lower grain growth rate and magnets made from the pre-alloy powder with a broader particle size distribution demonstrate a higher grain growth rate. It is believed that the presence of appropriate amounts of Nd oxides effectively impedes the grain growth process and a larger difference in sizes between pre-alloy powder particles significantly accelerates the grain growth process. On the basis of experimental results, the grain growth exponent and the corresponding activation energy were obtained. A possible grain growth mechanism in NdFeB magnets during sintering was briefly discussed.

Hydrogen Embrittlement Processes and Al/Al_2O_3 Hydrogen Resistance Coatings of NdFeB Magnets

After analyzing the phenomena and processes of hydrogen embrittlement of NdFeB permanent magnets, RF magnetron sputtering was used to fabricate Al thin films and then oxidized to form the Al/Al_2O_3 composite films on the magnets as the hydrogen resistance coatings. SEM and EDS were used to examine the morphology and composition respectively. Hydrogen resistance performance was tested by exposing the magnets in 10 MPa hydrogen gas at room temperature. The results show that the magnets with 8 μm Al/Al_2O_3 coatings can withstand hydrogen of 10 MPa for 65 min without being embrittled into powder. The samples with and without hydrogen resistance coatings have almost the same magnetic properties.

Factors Affecting the Squareness of Hysteresis Loops of Sintered NdFeB Magnets

Investigation into the magnets with different squareness of hysteresis loop(SHL) reveals that the microstructure of sintered NdFeB magnets has great effects on the SHL of the magnets. The abnormal grain growth deteriorates the SHL seriously. The shape of the grain and the grain boundary affect the intensity of demagnetization field, and consequently on the SHL. The added elements have effects on the phase structures and distributions in the magnets, which influences the uniform of demagnetization field.