Nd-Fe-B die-upset and anisotropic bonded magnets (invited)

The hot working conditions were examined for Nd-Fe-B die-upset magnets. The Nd14Fe80B6 ternary composition has the best workability (die upsetting) from stress-strain curves for the initial stage of die upsetting at hot working temperature. The compression ratio defined as the inverse of reduction in height should be larger than 4 to have materials aligned. Alignment of c axis along the compressive stress direction is obtained, but grain coarsening occurs during die upsetting. Of several additional elements investigated, Ga is the best for enhancing the coercivity with a little sacrifice of remanence and no deterioration in hot workability. Typical magnetic properties for Nd14Fe79.25B6Ga0.75 die-upset magnets are Br =12.4 kG, iHc =19 kOe, and (BH)max =36 MGOe. The irreversible loss after exposure up to 160 °C is under 10% (Pc =2). The iHc of powder made by crushing the die-upset magnets is nearly independent of particle size. Decrease in iHc by pulverizing to several hundred micron is about 2 kOe. Anisotropic bonded magnets were developed using this powder. Best energy products of injection and compression molded magnets with Ga addition are 10 and 15 MGOe, respectively. The irreversible losses after exposure up to 120 °C is lower than 5% (Pc =2), which is enough thermal stability for polymer-bonded magnets.