Effect of Al Content on Magnetic Properties of NdFeB/Al Magnet by Cold Spraying

This study investigates cold‐sprayed neodymium iron boron/aluminum (NdFeB/Al) composite magnets by varying Al content and particle size. Aluminum's high plastic deformability enables pore filling, enhancing density. Magnetic characterization shows 5 wt% fine Al yields optimal remanence (B r , magnetic induction retention), while 7.5 wt% Al enhances intrinsic coercivity (H cj , resistance to demagnetization). Excessive aluminum reduces NdFeB deposition efficiency. Maxwell simulations reveal Al particles disrupt magnetic flux propagation and alter flux lines at interfaces. Physically isolating NdFeB particles, Al forces independent demagnetization resistance, enhancing anisotropy field contributions and creating pinning sites. This work pioneers aluminum‐assisted cold spray additive manufacturing, overcoming low deposition efficiency and poor mechanical properties in conventional methods, enabling novel high‐performance permanent magnet fabrication.