Study on Ce₂Fe₁₄B-based sintered magnets with Ce/RE> 80%

Up to now, the development of Ce/RE> 80% sintered permanent magnets still faces a challenge, owing to their seriously deteriorated microstructure. In this article, the Ce25.5 similar to 31.5Nd0 similar to 5Febal.B1.25M1.15 (wt.%) sintered magnets with Ce/RE > 80% were investigated, the roles of minor Nd substitution were explored. The typical island-like phase common existed in the grain-boundary (GB) regions of Ce2Fe14B-based SC alloys (which destroys the continuity of RE-rich GB phase), was confirmed as a tetragonal B-rich phase (fct-RE5Fe18B18), and probably generated by the peritectic reaction of "L + Ce2Fe14B -> CeFe2 + B-rich" at 797 degrees C. It was found that: the deteriorated microstructures of high Ce sintered magnets were hardly improved (Nd element was not enriched in the main phase as it was expected), and the coercivity increments were far below expectations by directly adding 3-5% Nd in alloy designs. However, the GB phase distribution was more uniform and continuous, Nd-rich shells formed, and magnetic properties were remarkably promoted by blending 2% NdHx powders into the Ce27.5Nd3Febal.B1.25M1.15 (Ce27.5Nd3) magnet during JM milling, compared with the Ce25.5Nd5Febal.B1.25M1.15 (Ce25.5Nd5) magnet with similar composition. The good comprehensive magnetic properties of H-cj = 1.714 kOe, B-r = 9.395 kG, and (BH)(max) = 11.16 MGOe have been reached in the Ce27.5Nd3+2% (NdHx) magnet (Ce accounted for 84.5 wt% of total rare earth). The present work deepens our understanding of metallurgical behavior, process/microstructure designing for Ce/RE> 80% sintered magnets, and shed a light on the large-scale utilization of Ce element in a permanent magnet.