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Recent progress in the development of high-performance bonded magnets using rare earth-Fe compounds
Takashi Horikawa1,2, Masao Yamazaki1,2, Masashi Matsuura2
1Frontier Research and Development Division, Aichi Steel Corporation, Tokai, Japan.
This study reviews high-performance bonded magnets using neodymium-iron-boron (Nd-Fe-B) and samarium-iron (Sm-Fe) compounds. Bonded magnets offer a viable route for bulk magnet production, especially for Sm-Fe-based materials.
Area of Science:
- Materials Science
- Magnetism
- Permanent Magnets
Background:
- Rare earth magnets, particularly Nd-Fe-B, are crucial due to their magnetic properties.
- Established methods for Nd-Fe-B magnets include powder metallurgy for sintered magnets and melt-spinning or hydrogenation, disproportionation, desorption, and recombination (HDDR) for bonded magnets.
- Sm-Fe-based compounds like Sm2Fe17Nx and Sm(Fe,M)12 present challenges for high-performance sintered magnet production due to low decomposition temperatures and lack of suitable grain boundary phases.
Purpose of the Study:
- To review recent advancements in the development of high-performance bonded magnets.
- To explore the application of Nd2Fe14B and Sm2Fe17Nx compounds in bonded magnet technology.
- To highlight the utility of bonded magnets for Sm-Fe-based materials where sintering is difficult.
Main Methods:
- Utilizing melt-spinning or HDDR processes to produce magnet powders from Nd-Fe-B and Sm-Fe-based compounds.
- Mixing these magnet powders with binders to create composite materials for bonded magnets.
- Reviewing and analyzing the performance characteristics of the developed bonded magnets.
Main Results:
- Bonded magnets provide a practical method for fabricating bulk magnets from Sm-Fe-based compounds.
- High-performance bonded magnets have been successfully developed using both Nd2Fe14B and Sm2Fe17Nx compounds.
- This approach overcomes the limitations associated with liquid-phase sintering for certain advanced magnetic materials.
Conclusions:
- Bonded magnet technology is a key enabler for utilizing advanced rare earth magnetic compounds.
- The reviewed work demonstrates significant progress in creating high-performance Nd-Fe-B and Sm-Fe-based bonded magnets.
- Further development in bonded magnets is crucial for applications requiring strong permanent magnets, especially from challenging Sm-Fe systems.
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