Comprehensively improved magnetic performance of Nd-Fe-B magnets with high-efficiency grain boundary diffusion of heavy rare earth

Comprehensively improved magnetic performance Nd-Fe-B magnets with extremely limited amount of Heavy Rare Earth (HRE) elements are obtained to meet the increasingly demanding applications. In this work, Tb–Co thin film with uniform distribution, flat surface and strong adhesion is successfully prepared by magnetron sputtering, and the effects of Tb–Co film thickness on the magnetic properties are investigated. The magnets with optimal magnetic properties are achieved when the film thickness is about 3.5 μm, the coercivity of 1284.81 kA/m, the remanence of 1.48 T, and the maximum magnetic energy product of 437.32 kJ/m3, compared with the original magnets, enhancing by 47.9 %, 0.4 % and 5.7 %, respectively, so the magnetic properties have been comprehensively improved using little amount of HRE and Co elements. HRTEM and EPMA results revealed that Tb-rich shell distributed around the Nd2Fe14B grain. The mechanisms of the remanence and coercivity simultaneous enhancement of Nd-Fe-B magnets is elaborated in detail. Besides, the diffusion of Tb–Co thin film can enhance thermal stability of the magnets.