Dy evolution and coercivity improvement mechanism of sintered NdFeB magnets in thermal diffusion process

Heavy rare earth (such as Dy) thermal diffusion process is a promising method to increase the coercivity of sintered NdFeB magnets and optimizes their thermal performance. However, the Dy evolution process and the mechanism of coercivity improvement still require further clarification. In this work, commercial 30 M magnets were employed as the initial magnet, and a homemade DyF3 coating was prepared for thermal diffusion treatment. The optimal Dy diffusion process was obtained at 900 ℃ for 8 h. The coercivity of the magnet was increased from 14.16 kOe to 20.43 kOe with a negligible decrease in remanence. The Dy evolution process was systematically analyzed for understanding the mechanism of coercivity improvement. The diffusion coefficient was calculated based on Fick's second law. The diffusivity of Dy along the grain boundaries (5.16 × 10−8 cm2·s−1) is much higher than that in the grains (2.33 × 10−11 cm2·s−1). Therefore, the Dy diffused into the magnet along the grain boundaries with a faster diffusivity, forming uniform and continuous grain boundaries of the Dy-rich phases around the grains, which plays a decoupling effect and significantly increases the coercivity of the magnet. Simultaneously, the Dy in the grain boundaries diffused into the main phase with a slower diffusivity to form a (Nd, Dy)2Fe14B thin layer with higher magnetocrystalline anisotropic, which can inhibit the nucleation of reversed magnetic domains and further improve intrinsic coercivity. However, over diffusion process led to the excess Dy diffused into the grain, which will decrease the performance of the magnet. This work provides an insight of Dy evolution process during the diffusing period, and is significant to understand the improvement mechanism of coercivity for preparing NdFeB magnets with high-performance and low cost.