On dysprosium utilisation in multi-main-phase Nd–Dy–Fe–B magnets with core–shell microstructures

Zhang, Zhiheng; Chen, Hansheng; Jin, Jiaying; Lim, Bryan; Liu, Xiaolian; Li, Wei; Yan, Mi; Ringer, Simon P.

doi:10.1016/j.actamat.2023.119344

Title: On dysprosium utilisation in multi-main-phase Nd–Dy–Fe–B magnets with core–shell microstructures

Journal Article · 11 September 2023 · Acta Materialia

DOI: https://doi.org/10.1016/j.actamat.2023.119344 · OSTI ID:2426053

^[1];

^[2]; Jin, Jiaying ^[1];

^[3]; Liu, Xiaolian ^[4]; Li, Wei ^[5]; Yan, Mi ^[1]; Ringer, Simon P. ^[2]

Zhejiang Univ., Hangzhou (China)
Univ. of Sydney, NSW (Australia)
Univ. of Sydney, NSW (Australia); Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Hangzhou Dianzi University (China)
Nanchang Hangkong University (China)

The development of high-performance Nd–Dy–Fe–B magnets that minimise the consumption of the scarce rare earth (RE) element Dy remains a major global scientific and technological quest. Here, we designed an alloy microstructure comprising of a uniform Dy-lean core–Dy-rich shell in a series of multi-main-phase (MMP) Nd–Dy–Fe–B magnets. The resulting MMP Dy1 and Dy3 magnets with an overall Dy level of 1 and 3 wt.% possessed values of 0.48 and 0.29 T/wt.% of coercivity increment per unit weight percentage of the Dy addition, respectively. Most importantly, the resulting MMP Dy3 magnet exhibited a high coercivity (2.38 T), an excellent thermal stability of the coercivity (|β| = 0.531%/°C), a high squareness factor (> 95%), all with little diminishment in the remanent magnetisation (1.35 T) and maximum energy product (43.6 MGOe). These properties are superior to the currently available sintered Nd–Dy–Fe–B magnets which utilise higher levels of Dy of 5 wt.%. Via magnetic and multi-scale microstructural characterisation experiments and micromagnetic simulations, the formation of the Dy-lean core–Dy-rich shell microstructure is rationalised via solid-state-diffusion and solution reprecipitation during liquid-phase sintering. The Dy-lean core–Dy-rich shell microstructure and the non-ferromagnetic low-Fe RE-rich grain boundary phase led to the synergistic magnetic performance. This is significant in the context of the MMP Nd–Dy–Fe–B magnets being applied to large-scale production. The present work establishes a pathway for the more sustainable utilisation of Dy in permanent magnets via formation of a uniform core–shell microstructure.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE; National Key Research and Development Program of China; National Natural Science Foundation of China (NSFC); Key Research and Development Program of Zhejiang Province

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2426053

Journal Information:: Acta Materialia, Journal Name: Acta Materialia Vol. 261; ISSN 1359-6454

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Title: On dysprosium utilisation in multi-main-phase Nd–Dy–Fe–B magnets with core–shell microstructures

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