Carbide/nitride grain refined rare earth-iron-boron permanent magnet and method of making

A method of making a permanent magnet wherein 1) a melt is formed having a base alloy composition comprising RE, Fe and/or Co, and B (where RE is one or more rare earth elements) and 2) TR (where TR is a transition metal selected from at least one of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, and Al) and at least one of C and N are provided in the base alloy composition melt in substantially stoichiometric amounts to form a thermodynamically stable compound (e.g. TR carbide, nitride or carbonitride). The melt is rapidly solidified in a manner to form particulates having a substantially amorphous (metallic glass) structure and a dispersion of primary TRC, TRN and/or TRC/N precipitates. The amorphous particulates are heated above the crystallization temperature of the base alloy composition to nucleate and grow a hard magnetic phase to an optimum grain size and to form secondary TRC, TRN and/or TRC/N precipitates dispersed at grain boundaries. The crystallized particulates are consolidated at an elevated temperature to form a shape. During elevated temperature consolidation, the primary and secondary precipitates act to pin the grain boundaries and minimize deleterious grain growth that is harmful to magnetic properties

Carbide/nitride grain refined rare earth-iron-boron permanent magnet and method of making

A method of making a permanent magnet wherein 1) a melt is formed having a base alloy composition comprising RE, Fe and/or Co, and B (where RE is one or more rare earth elements) and 2) TR (where TR is a transition metal selected from at least one of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, and Al) and at least one of C and N are provided in the base alloy composition melt in substantially stoichiometric amounts to form a thermodynamically stable compound (e.g. TR carbide, nitride or carbonitride). The melt is rapidly solidified in a manner to form particulates having a substantially amorphous (metallic glass) structure and a dispersion of primary TRC, TRN and/or TRC/N precipitates. The amorphous particulates are heated above the crystallization temperature of the base alloy composition to nucleate and grow a hard magnetic phase to an optimum grain size and to form secondary TRC, TRN and/or TRC/N precipitates dispersed at grain boundaries. The crystallized particulates are consolidated at an elevated temperature to form a shape. During elevated temperature consolidation, the primary and secondary precipitates act to pin the grain boundaries and minimize deleterious grain growth that is harmful to magnetic properties

Dependence of energy dissipation on annealing temperature of melt–spun NdFeB permanent magnet materials

A model of magnetic hysteresis which was developed originally for soft magnetic materials has been applied to melt–spun ribbons of Nd2Fe14B‐based material. The crucial ideas in the model description of hysteresis center on a dissipation of energy due to hysteresis which is proportional to the change in magnetization. The Nd2Fe14B material was melt–spun amorphous and then annealed for a period of 24 h at temperatures ranging from 700 to 950 °C. This resulted in different grain sizes, depending on annealing temperature. Consequently the hysteresis curves represent the properties of the material as a function of both annealing temperature and grain size. It was found that the magnetic properties varied systematically with annealing temperature, and hence grain size, as would be expected. When modeling the magnetic properties it was found that the model parameters also varied systematically, in particular, the energy dissipation parameter k was to a first approximation a simple linear function of the annealing temperature and decreased with increasing annealing temperature as a result of grain growth. Therefore, this study revealed a basic relationship between materials processing conditions, microstructure, model parameters, and magnetic properties

Site-preference and valency for rare-earth sites in (R-Ce)2Fe14B magnets

Rare-earth (R) permanent magnets of R2Fe14B have technological importance due to their high energy products, and they have two R-sites (Wyckoff 4f and 4g, with four-fold multiplicity) that affect chemistry and valence. Designing magnetic behavior and stability via alloying is technologically relevant to reduce critical (expensive) R-content while retaining key properties;cerium, an abundant (cheap) R-element, offers this potential. We calculate magnetic propertiesand Ce site preference in ( R1−xCex) 2Fe14B [R = La,Nd] using density functional theory (DFT)methods—including a DFT + U scheme to treat localized 4f-electrons. Fe moments compare well with neutron data—almost unaffected by Hubbard U, and weakly affected by spin-orbit coupling.In La2Fe14B, Ce alloys for 0≤x≤1 and prefers smaller R(4f) sites, as observed, a trend we find unaffected by valence. Whereas, in Nd2Fe14B, Ce is predicted to have limited alloying ( x≤0.3 ) with a preference for larger R(4g) sites, resulting in weak partial ordering and segregation. The Curie temperatures versus x for (Nd,Ce) were predicted for a typical sample processing and verified experimentally

Structural and magnetic properties of Ti4+/Co2+ co-substituted cobalt ferrite

The variations in the structural magnetic properties of cobalt ferrite due to Ti4+/Co2+ co-substitution for 2Fe3+ are presented. The non-linear relation in the variation of the lattice parameter agrees with a previous study on cation distribution, which showed that the rate of substitution of cations into the A-sites and B-sites varies with Ti-concentration. Such variation in the rate of substitution into the cation sites was also observed in the magnetization, coercive field, and susceptibility data. The coercive field and differential susceptibility are inversely related. Although the coercive field of the Ti-substituted cobalt ferrite generally decreased compared to the un-substituted cobalt ferrite, magnetic susceptibility was higher at higher Ti-concentrations

Method of making bonded or sintered permanent magnets

An isotropic permanent magnet is made by mixing a thermally responsive, low viscosity binder and atomized rare earth-transition metal (e.g., iron) alloy powder having a carbon-bearing (e.g., graphite) layer thereon that facilitates wetting and bonding of the powder particles by the binder. Prior to mixing with the binder, the atomized alloy powder may be sized or classified to provide a particular particle size fraction having a grain size within a given relatively narrow range. A selected particle size fraction is mixed with the binder and the mixture is molded to a desired complex magnet shape. A molded isotropic permanent magnet is thereby formed. A sintered isotropic permanent magnet can be formed by removing the binder from the molded mixture and thereafter sintering to full density

Method of making bonded or sintered permanent magnets

An isotropic permanent magnet is made by mixing a thermally responsive, low viscosity binder and atomized rare earth-transition metal (e.g., iron) alloy powder having a carbon-bearing (e.g., graphite) layer thereon that facilitates wetting and bonding of the powder particles by the binder. Prior to mixing with the binder, the atomized alloy powder may be sized or classified to provide a particular particle size fraction having a grain size within a given relatively narrow range. A selected particle size fraction is mixed with the binder and the mixture is molded to a desired complex magnet shape. A molded isotropic permanent magnet is thereby formed. A sintered isotropic permanent magnet can be formed by removing the binder from the molded mixture and thereafter sintering to full density

Method of making permanent magnets

A method for making an isotropic permanent magnet comprises atomizing a melt of a rare earth-transition metal alloy (e.g., an Nd--Fe--B alloy enriched in Nd and B) under conditions to produce protectively coated, rapidly solidified, generally spherical alloy particles wherein a majority of the particles are produced/size classified within a given size fraction (e.g., 5 to 40 microns diameter) exhibiting optimum as-atomized magnetic properties and subjecting the particles to concurrent elevated temperature and elevated isotropic pressure for a time effective to yield a densified, magnetically isotropic magnet compact having enhanced magnetic properties and mechanical properties.</p

Temperature dependence of the magnetomechanical effect in metal-bonded cobalt ferrite composites under torsional strain

Metal-bonded cobaltferrite composites are promising candidates for torquesensors and other magnetostrictive sensing and actuating applications. In the present study, the temperature dependence of the magnetomechanical effect in a ring-shape cobaltferrite composite under torsional strain has been investigated in the temperature range of −37 to 90 °C. The changes of external axial magnetic field were measured as a function of applied torque. Magnetomechanical sensitivity of ΔHext/Δτ=65 A N−1 m−2 was observed with a magnetomechanical hysteresis of Δτ=±0.62 N m at room temperature (22 °C). These were then measured as a function of temperature. Both decreased as the temperature increased throughout the entire range. The magnetomechanical hysteresis became negligible at temperatures higher than 60 °C, above which there was a linear change in external magnetic field with applied torque. These temperature dependences are explained by the changes of magnetostriction, anisotropy, spontaneous magnetization, and pinning of domain walls caused by the availability of increased thermal energy