Enhancement of the magnetic property of Nd-Fe-B sintered magnets through novel powder rounding modification

Two types of sintered Nd-Fe-B magnets were fabricated by the process of powder metallurgy technology through two different powder preparation processes i.e., conventional powder preparation process and novel powder rounding modification. The microstructure, composition and properties of the two type powders have been studied including the particle size distributions and flowabilities. Furthermore, magnetic properties, microstructure and alignment degree of the magnets prepared by the corresponding powder also have been investigated. The novel powder rounding modification rounds the sharp edges and corners of the particles compared to the conventional powder preparation process, thereby reducing friction between the particles and improving flowability of the powder. As a result, the alignment degree of the sintered magnet is enhanced, which contribute to the improvement of the remanence and the energy product density. The powder that experienced rounding process changed the distribution of RE (rare earth)-rich particles, causing tiny RE-rich particles to adhere around the main phase particles, facilitating the compact of bulk during liquid-phase sintering process and achieving uniform distribution of RE-rich phases around the Nd2Fe14B main phase, resulting in increasing the magnet density and coercivity. As a consequence, we have produced the magnet with Br = 1.43 T, Hcj = 1049 kA/m and (BH)max = 393.2 kJ/m3, which is fully superior to conventional magnet with Br = 1.41 T, Hcj = 969 kA/m and (BH)max = 383.7 kJ/m3 by adopting powder rounding process. This indicates that the novel powder rounding modification is an efficient approach for synchronous improvement of magnetic performance of sintered Nd-Fe-B without any heavy rare earth elements.