I.E. Anderson

New YDy-Based R2(Fe,Co)14B Melt-Spun Magnets (R=Y+Dy+Nd)

The effects of the ratio of Y to Dy as well as the effect of Nd and Co substitutions on magnetic properties in [Ndx(YDy)0.5(1-x)]2.2Fe14-yCoyB ribbons melt-spun at 22 m/s have been systematically studied. (Y1-zDyz)2.2Fe14B ribbons with a ratio z of 0.25 or 0.5 simultaneously obtains a smaller temperature coefficient of remanence (α ) and coervicity (β ) which are much smaller than those of Nd-based Nd2Fe14B ribbons. In [Ndx(YDy)0.5(1-x)]2.2Fe14-yCoyB ribbons, Nd substitution (x=0 to 0.8) can improve the maximum energy product (BH)max of annealed ribbons but degrades the temperature stability of the magnetic properties. The ribbons with x=0.4 and y=0 yield a (BH)max of 8.7 MGOe. For these ribbons, the α and β are -0.07 and -0.31 %/°C in the temperature range of 27 to 127°C, respectively. Increasing Co (x) from 0 to 3, slightly decreases coercivity Hcj from 21.5 to 16.3 kOe, but keeps the (BH)max in the range of 8.6 to 10.2 MGOe. The optimal sample with x=0.5 and y=1.5 obtains a (BH)max of 10.2 and 5.0 MGOe at 27 and 250°C, respectively. Its α and β are -0.11 and -0.30 %/°C, respectively. These results show that studied ribbons are very promising to develop into high temperature isotropic bonded magnets capable of operating at or above 180°C.

Microstructural and magnetic property evolution with different heat-treatment conditions in an alnico alloy

Abstract Further property enhancement of alnico, an attractive near-term, non-rare-earth permanent magnetxa0alloy system, primarily composed of Al, Ni, Co, and Fe, relies on improved morphology control and size refinement of its complex spinodally decomposed nanostructure that forms during heat-treatment. Using a combination of transmission electron microscopy and atom probe tomography techniques, this study evaluates the magnetic properties and microstructures of an isotropic 32.4Fe-38.1Co-12.9Ni-7.3Al-6.4Ti-3.0Cu (wt.%) alloy in terms of processing parameters such as annealing temperature, annealing time, application of an external magnetic field, as well as low-temperature “draw” annealing. Optimal spinodal morphology and spacing is formed within a narrow temperature and time range (∼ 840xa0°C and 10xa0min) during thermal-magnetic annealing (MA). The ideal morphology is a mosaic structure consisting of periodically arrayed ∼ 40xa0nm diameter (Fe-Co)-rich rods ( α 1 phase) embedded in an (Al-Ni)-rich ( α 2 phase) matrix. A Cu-enriched phase with a size of ∼ 3–5xa0nm is located at the corners of two adjacent { 110 } facets of the α 1 phase. The MA process significantly increased remanence ( B r ) (∼ 40–70%) of the alloy due to biased elongation of the α 1 phase along the 〈 100 〉 crystallographic direction, which is closest in orientation to the applied magnetic field. The optimum magnetic properties of the alloy with an intrinsic coercivity ( H cj ) of 1845xa0Oe and a maximum energy product ( B H max ) of 5.9 MGOe were attributed to the uniformity of the mosaic structure.

Simulation of alnico coercivity

Micromagnetic simulations of alnico show substantial deviations from Stoner-Wohlfarth behavior due to the unique size and spatial distribution of the rod-like Fe-Co phase formed during spinodal decomposition in an external magnetic field. The maximum coercivity is limited by single-rod effects, especially deviations from ellipsoidal shape, and by interactions between the rods. Both the exchange interaction between connected rods and magnetostatic interaction between rods are considered, and the results of our calculations show good agreement with recent experiments. Unlike systems dominated by magnetocrystalline anisotropy, coercivity in alnico is highly dependent on size, shape, and geometric distribution of the Fe-Co phase, all factors that can be tuned with appropriate chemistry and thermal-magnetic annealing.

Net Shape Processing of Alnico Magnets by Additive Manufacturing

Alternatives to rare earth permanent magnets, such as alnico, will reduce supply instability, increase sustainability, and could decrease the cost of permanent magnets, especially for high-temperature applications, such as traction drive motors. Alnico magnets with moderate coercivity, high remanence, and relatively high-energy product are conventionally processed by directional solidification and (significant) final machining, contributing to increased costs and additional material waste. Additive manufacturing (AM) is developing as a cost effective method to build net-shape 3-D parts with minimal final machining and properties comparable to wrought parts. This paper describes initial studies of net-shape fabrication of alnico magnets by AM using a laser engineered net shaping (LENS) system. High-pressure gas atomized pre-alloyed powders of two different modified alnico “8” compositions, with high purity and sphericity, were built into cylinders using the LENS process, and followed by heat treatment. The magnetic properties showed improvement over their cast and sintered counterparts. The resulting alnico permanent magnets were characterized using scanning electron microscopy, energy dispersive spectroscopy, electron backscatter diffraction, and hysteresisgraph measurements. These results display the potential for net-shape processing of alnico permanent magnets for use in next generation traction-drive motors and other applications requiring high temperatures and/or complex engineered part geometries.

On spinodal decomposition in alnico - A transmission electron microscopy and atom probe tomography study

Abstract Alnico is a prime example of a finely tuned nanostructure whose magnetic properties are intimately connected to magnetic annealing (MA) during spinodal transformation and subsequent lower temperature annealing (draw) cycles. Using a combination of transmission electron microscopy and atom probe tomography, we show how these critical processing steps affect the local composition and nanostructure evolution with impact on magnetic properties. The nearly 2-fold increase of intrinsic coercivity (Hci) during the draw cycle is not adequately explained by chemical refinement of the spinodal phases. Instead, increased Fe-Co phase (α1) isolation, development of Cu-rich spheres/rods/blades and additional α1 rod precipitation that occurs during the MA and draw, likely play a key role in Hci enhancement. Chemical ordering of the Al-Ni-phase (α2) and formation of Ni-rich (α3) may also contribute. Unraveling of the subtle effect of these nano-scaled features is crucial to understanding on how to improve shape anisotropy in alnico magnets.