Search Results (10)

In this paper, the magnetic properties of HDDR NdFeB powders were improved by the grain boundary diffusion of Cu₂₈Ce₇₂ alloy. The influence and mechanism of Cu₂₈Ce₇₂ alloy and heating process on the coercivity (H_cj), remanence (B_r), and maximum magnetic energy product (BH_max) of magnetic powders were investigated. The grain boundary diffusion of Cu₂₈Ce₇₂ alloy can effectively improve the H_cj, B_r and BH_max of bonded magnets, exhibiting a trend of first increasing and then decreasing with the increase in diffusion temperature and Cu₂₈Ce₇₂ addition, and the maximum values of 927 kA/m, 0.625 T and 61 kJ/m³ are obtained at the Cu₂₈Ce₇₂ content of 5.0 wt% and the heating temperature of 380 °C. The demagnetization coupling effect is increased by a continuous grain boundary phase formed by the diffusion of Ce and Cu elements into the grain boundaries, and thus the coercivity of magnetic powder is improved. During the diffusion process, Ce element diffuses along the grain boundaries to repair the defective areas around the grains and form a Ce₂Fe₁₄B phase, which improves the H_cj and B_r of magnetic powders; on the other hand, Ce element diffuses into Nd₂Fe₁₄B grains to replace the Nd crystal sites, reducing the H_cj and B_r of magnet; therefore, the H_cj and B_r of HDDR NdFeB powders are comprehensively affected by these two aspects. Full article

This article investigates the connection between the process parameters of solid hydrogenation, disproportionation (HD), desorption, and recombination (DR) (HDDR) in sintered (Nd,Pr,Gd)-Fe-B magnets, as well as their phase composition and degree of texture (DoT). During HD, hydrogen pressures of 10–50 kPa were applied at temperatures ranging from 700 to 785 °C for reaction times ranging from 3 to 11 h. DR was performed at 750–850 °C. The HD reaction was observed across the full range of hydrogen pressure and temperature. The phase composition of the disproportionation products depends on the depth in the sample. Applying HDDR treatment at a pressure of 10 kPa is an effective way to increase the DoT of magnets. Magnets are anisotropic following the HDDR treatment across the parameter ranges. The dependence of the DoT value on HDDR treatment parameters is complicated, with the main trend being a decline in DoT with increasing hydrogen pressure. The DoT is determined by the disproportionation and recombination temperatures, as well as the depth at 50 kPa pressure. The recombined phase is isotropic near the sample surface and highly anisotropic within the sample after 50 kPa is applied. Full article

By incorporating various types of permanent magnetic powders, composite magnets with cost-effectiveness and a wide range of magnetic properties can be achieved. In this study, the anisotropic composite magnets were fabricated using the hot press forming method, which involved blending neodymium iron boron (NdFeB) powder and samarium iron nitrogen (SmFeN) powder. The experiment demonstrated that the magnet density reaches its maximum point when the doping level of SmFeN reaches 20 wt.%, aligning remarkably well with the corresponding theoretical value of 19.22 wt.% achieved through a cubic stacking arrangement. In the absence of an applied magnetic field or under a sufficiently high oriented magnetic field (3 T), the remanence variation pattern in composite magnets doped with different amounts of SmFeN aligns consistently with the density pattern, yielding a maximum value of 20%. However, in the actual solidification process, the orientation field is insufficient (e.g., 1.5 T), necessitating a doping amount that exceeds the value corresponding to peak density by 28% to achieve optimal remanence. This observation suggests that the incorporation of a higher proportion of small-sized and relatively low coercivity SmFeN magnetic powder can effectively facilitate the rotational alignment of neighboring large-sized NdFeB magnetic powder under weak magnetic fields, thereby inducing a synergistic effect. Full article

Hydrogenation–Disproportionation–Desorption–Recombination (HDDR) Nd₂Fe₁₄B particles have excellent magnetic properties, but the magnetic properties of powder are not uniform across different particle sizes. The remanence and maximum magnetic energy products of samples with a particle size of 120 μm are 14.0 kGs and 41.35 MGOe, while the products of samples with a particle size of 60 μm are only 13.3 kGs and 36.31 MGOe. The macroscopic morphology of HDDR Nd₂Fe₁₄B particles and the gradient distribution of microstructures in different micro-regions were observed. By modifying the macroscopic morphology of the particles, the poorly oriented clusters on the surface of the particles were precisely eliminated, and the remanence and maximum magnetic energy products of the particles increased to 14.5 kGs and 45 MGOe, respectively. Compared with the original particles, the samples after mechanical grinding had better grain arrangement. The effects of the nanocrystalline c-axis and field misalignment angle θ on the magnetic properties of HDDR Nd₂Fe₁₄B particles were investigated through micromagnetic simulation. The targeted removal of macroscopic defects on the particle surface contributed to a 3.6% increase in remanence and an 8.8% increase in the maximum magnetic energy product, offering a promising approach to enhance the microstructure of high-performance HDDR Nd₂Fe₁₄B particles. Full article

We investigate the effect of an applied magnetic field on the entire HDDR process using a customized reactor vessel and a warm-bore superconducting magnet. We analyzed the resulting properties produced at both a 0 applied field and a 2 Tesla applied field. We show that the application of a magnetic field throughout the HDDR process results in powders that exhibit a greater level of anisotropy compared to their ambient field counterparts. Full article

We propose a method of manipulating the coercivity of anisotropic hydrogenation-disproportionation-desorption-recombination (HDDR) powders to fabricate high-remanence and fine-grained Nd-Fe-B magnets using only hot-pressing without a subsequent hot-deformation process. By reducing the Nd content of anisotropic HDDR precursors such that their coercivity (H_cj) is lowered, the c-axis of each HDDR particle is well-aligned parallel to the direction of the applied magnetic field during the magnetic alignment step. This is because the magnetic repulsive force between adjacent particles, determined by their remanent magnetization, decreases as a result of the low coercivity of each particle. Therefore, after hot-pressing the low-H_cj HDDR powders, a significantly higher remanence (11.2 kG) is achieved in the bulk than that achieved by hot-pressing the high-H_cj HDDR powders (8.2 kG). It is clearly confirmed by the large-scale electron backscatter diffraction (EBSD) analysis that the alignment of the c-axis of each anisotropic HDDR particle in the bulk is improved when low-H_cj HDDR powders are used to fabricate hot-pressed magnets. This coercivity manipulation of HDDR powders can be a helpful method to expand the use of HDDR powders in fabricating anisotropic Nd-Fe-B bulk magnets. Full article

Neodymium-Iron-Boron (NdFeB) based permanent magnets are indispensable in today’s technology-driven society. Moreover, their use is likely to increase since they are key in clean energy applications such as wind turbines, hybrid/electric vehicles, and electric bikes. They contain critical raw materials as rare earth elements are used. Indeed, permanent magnets are considered strategic materials by the EU, and their recycling represents a potential secondary supply to decrease the import dependence. The VALOMAG project is developing a technical solution to recover rare earth (RE) based permanent magnets by dismantling end-of-life (EoL) products such as computer hard disc drives, electric motors, and generators from electric vehicles and wind turbines. It also assesses two short loop recycling technologies: Hydrogen Decrepitation (HD) or Hydrogenation–Disproportionation–Desorption–Recombination (HDDR) and strip-casting for high and medium quality magnet wastes; and hydrometallurgical processes for EoL low-quality magnets. Moreover, Life Cycle Assessment (LCA) and Process Integration with a Flowsheet simulation tool will integrate the whole recycling value chain (collection, dismantling, physical and chemical treatment options, and re-manufacturing) and assess the environmental impact and processes efficiency. A market study on the types and expected future quantities for the scrap magnets and the characterisation of the EoL magnets from hard disc drives (HDD) will be presented as preliminary results. Pre-treatment and sorting of 2.5 tons of NdFeB magnets scraps were carried out, and the two short loop recycling routes and the hydrometallurgical route are under investigation at the lab and pilot scale. The results will be used to develop a process integration and to assess the three routes through LCA. Full article

Fully dense spark plasma sintered recycled and fresh HDDR Nd-Fe-B nanocrystalline bulk magnets were processed by surface grain boundary diffusion (GBD) treatment to further augment the coercivity and investigate the underlying diffusion mechanism. The fully dense SPS processed HDDR based magnets were placed in a crucible with varying the eutectic alloys Pr₆₈Cu₃₂ and Dy₇₀Cu₃₀ at 2–20 wt. % as direct diffusion source above the ternary transition temperature for GBD processing followed by secondary annealing. The changes in mass gain was analyzed and weighted against the magnetic properties. For the recycled magnet, the coercivity (H_Ci) values obtained after optimal GBDP yielded ~60% higher than the starting recycled HDDR powder and 17.5% higher than the SPS-ed processed magnets. The fresh MF-15P HDDR Nd-Fe-B based magnets gained 25–36% higher coercivities with Pr-Cu GBDP. The FEG-SEM investigation provided insight on the diffusion depth and EDXS analysis indicated the changes in matrix and intergranular phase composition within the diffusion zone. The mechanism of surface to grain boundary diffusion and the limitations to thorough grain boundary diffusion in the HDDR Nd-Fe-B based bulk magnets were detailed in this study. Full article

The low-pressure hot-deformation methodology was applied to reprocess the nanocrystalline hydrogenation–disproportionation–desorption–recombination (HDDR) Nd-Fe-B powders from end-of-life (EOL) permanent magnets’ waste to determine the mechanism of texture development and the resultant improvement in remanence (and BH_max) in the recycled material. Both the hot-pressed and hot-deformed magnets produced via spark plasma sintering (SPS) were compared in terms of their magnetic properties with respect to forging pressures. Also, a comparison was established with the microstructure to cite the effectiveness of texture development at low deformation rates and pressures which is pivotal for retaining high coercivity. The hot-pressed magnets maintain the high coercivity (better than 100%) of the original recycled powder due to the control of SPS conditions. The hot deformation pressure was varied from 100–150 MPa at 750 °C processing temperature to identify the optimal texture development in the sintered HDDR Nd-Fe-B magnets. The effect of post-hot-deformation thermal treatment was also investigated, which helped in boosting the overall magnetic properties and better than the recycled feedstock. This low-pressure hot deformation process improved the remanence of the hot-pressed magnet by 11% over the starting recycled powder. The M_r/M_S ratio which was 0.5 for the hot-pressed magnets increased to 0.64 for the magnets hot-deformed at 150 MPa. Also, a 55% reduction in height of the sample was achieved with the c-axis texture, indicating approximately 23% higher remanence over the isotropic hot-pressed magnets. After hot deformation, the intrinsic coercivity (H_Ci) of 960 kA/m and the remanence (B_r) value of 1.01 T at 150 MPa is indicative that the controlled SPS reprocessing technique can prevent microstructure related losses in the magnetic properties of the recycled materials. This route also suggests that the scrap Nd-Fe-B magnets can be treated with recoverable magnetic properties subsequently via HDDR technique and controlled hot deformation with a follow-up annealing. Full article

The magnetic properties of the recycled hydrogenation disproportionation desorption recombination (HDDR) Nd-Fe-B powder, doped with a low weight fraction of DyF₃ nanoparticles, were investigated. Spark plasma sintering (SPS) was used to consolidate the recycled Nd-Fe-B powder blends containing 1, 2, and 5 wt.% of DyF₃ grounded powder. Different post-SPS sintering thermal treatment conditions (600, 750, and 900 °C), for a varying amount of time, were studied in view of optimizing the magnetic properties and developing characteristic core-shell microstructure in the HDDR powder. As received, recycled HDDR powder has coercivity (H_Ci) of 830 kA/m, and as optimally as SPS magnets reach 1160 kA/m, after the thermal treatment. With only 1–2 wt.% blended DyF₃, the H_Ci peaked to 1407 kA/m with the thermal treatment at 750 °C for 1 h. The obtained H_Ci values of the blend magnet is ~69.5% higher than the starting recycled HDDR powder and 17.5% higher than the SPS processed magnet annealed at 750 °C for 1 h. Prolonging the thermal treatment time to 6 h and temperature conditions above 900 °C was detrimental to the magnetic properties. About ~2 wt.% DyF₃ dopant was suitable to develop a uniform core-shell microstructure in the HDDR Nd-Fe-B powder. The Nd-rich phase in the HDDR powder has a slightly different and fluorine rich composition i.e., Nd-O-F₂ than in the one reported in sintered magnets (Nd-O-F). The composition of reaction zone-phases after the thermal treatment and Dy diffusion was DyF₄, which is more abundant in 5 wt.% doped samples. Further doping above 2 wt.% DyF₃ is ineffective in augmenting the coercivity of the recycled HDDR powder, due to the decomposition of the shell structure and formation of non-ferromagnetic rare earth-based complex intermetallic compounds. The DyF₃ doping is a very effective single step route in a controlled coercivity improvement of the recycled HDDR Nd-Fe-B powder from the end of life magnetic products. Full article