Towards Production of Cost-Effective Modification of SmCo5-Type Alloys Suitable for Permanent Magnets.

SmCo5 constitutes one of the strongest classes of permanent magnets, which exhibit magnetocrystalline anisotropy with uniaxial character and enormous energy and possess high Curie temperature. However, the performance of SmCo5 permanent magnets is hindered by a limited energy product and relatively high supply risk. Sm is a moderately expensive element within the lanthanide group, while Co is a more expensive material than Fe, making SmCo5-based permanent magnets among the most expensive materials in the group. Subsequently, the need for new materials with less content in critical and thus expensive resources is obvious. A promising path of producing new compounds that meet these requirements is the chemical modification of established materials used in PM towards the reduction of expensive resources, for example, reducing Co content with transition metals (like Fe, Ni) or using as substitutes raw rare earth materials with greater abundance than global demand, like Ce and La. Important instruments to achieve these goals are theoretical calculations, such as ab initio methods and especially DFT-based calculations, in predicting possible stable RE-TM intermetallic compounds and their magnetic properties. This review aims to present the progress of recent years in the production of improved SmCo5-type magnets.

Scientific and technological analysis of exchange-spring magnets: Applications and trends.

In this work, a bibliometric study was carried out to perform a scientific and technological analysis of exchange-spring magnets, an alternative permanent magnet synthesized by reducing or eliminating the use of critical raw materials, such as rare earths. The bibliometric analysis utilized the Scopus database, Orbit-Intellixir, VOSviewer, Orbit-Intelligence and Loglet Lab 4 software for maturity analysis, keyword network representations, charts and graphs for scientific articles and/or patents. A special analysis was performed on nanocomposite and thin-films systems based on Nd-Fe-B, SmCo5 and Mn-Al-C alloys, either mixed or layered with a soft magnetic phase, where relevant information on their magnetic parameters was compilated in tables, highlighting the nanostructured systems that have been exhibited the best permanent magnet properties. The bibliometric analysis revealed that the primary production of scientific articles is concentrated in industrialized countries, and they are predominantly published in journals dedicated to magnetism. A patents analysis showed that Nissan motors is by far the main applicant, with most of its patents is focused on technological domains related to electrical machinery, apparatus, energy and metallurgy. On the other hand, the S-curve of maturity for scientific articles indicated that the study of exchange-spring magnets is entering a mature state. In contrast, patent production, following a bi-logistic model, is in a saturation stage for the second S-curve. Maturity analyses, employing S-curve, bi-logistic and multi-logistic models, were performed on nanocomposites and thin films based on Nd-Fe-B, SmCo5 and Mn-Al-C alloys, respectively. We found that the investigation in Nd-Fe-B-based alloys is close to enter to a scientific saturation stage, while an average growth stage is observed for the SmCo5 and Mn-Al-C-based alloys. This suggests that research on alternative magnets, capable of fulfilling technological applications where a Nd-Fe-B magnets are commonly used, is a topic of significant interest.

Hard Magnetic Properties and the Features of Nanostructure of High-Temperature Sm-Co-Fe-Cu-Zr Magnet with Abnormal Temperature Dependence of Coercivity.

This paper presents methods and approaches that can be used for production of Sm-Co-Fe-Cu-Zr permanent magnets with working temperatures of up to 550 °C. It is shown that the content of Sm, Cu, and Fe significantly affects the coercivity (Hc) value at high operating temperatures. A decrease in the content of Fe, which replaces Co, and an increase in the content of Sm in Sm-Co-Fe-Cu-Zr alloys lead to a decrease in Hc value at room temperature, but significantly increase Hc at temperatures of about 500 °C. Increasing the Cu concentration enhances the Hc values at all operating temperatures. From analysis of the dependence of temperature coefficients of the coercivity on the concentrations of various constituent elements in this alloy, the optimum chemical composition that qualifies for high-temperature permanent magnet (HTPM) application were determined. 3D atom probe tomography analysis shows that the nanostructure of the HTPM is characterized by the formation of Sm2(Co,Fe)17 (2:17) cells relatively smaller in size along with the slightly thickened Sm(Co,Cu)5 (1:5) boundary phase compared to those of the high-energy permanent magnet compositions. An inhomogeneous distribution of Cu was also noticed in the 1:5 phase. At the boundary between 1:5 and 2:17 phases, an interface with lowered anisotropy constants has developed, which could be the reason for the observed high coercivity values.

Effects of Ni and Cu Residuals on the Magnetic Properties and Microstructure of SmCo5 Magnets.

The effect of Ni/Cu-coating residuals on the magnetic properties and microstructures of samarium-cobalt (SmCo5) magnets was studied. SmCo5 magnets with 0.0, 0.5, 1.0, 2.0, 3.0 and 4.0 wt.% of added Ni/Cu (85 wt.% Ni/15 wt.% Cu) were prepared using a conventional sintering route. The magnetic properties of the magnets were found to be consistent up to 2 wt.% Ni/Cu. Any further increase in the Ni/Cu content resulted in a significant reduction in the magnetic properties, to lower than values that would be commercially acceptable. SEM/EDS studies showed that two major phases, i.e., the SmCo5 matrix phase and Sm2O3 were present in all the sintered SmCo5 magnets. The presence of Sm2Co7 as a minor phase fraction was detected in the sintered SmCo5 magnets containing up to 2 wt.% Ni/Cu. A 2 wt.% Ni/Cu addition to magnets resulted in the presence of two new phases with compositions close to SmCo and Sm2Co17 in addition to SmCo5 and Sm2O3 as major phases in the SEM-observed microstructure. These newly formed phases are present in small fractions and are presumably homogenously distributed at the grain boundaries of the magnets. As they are known to act as nucleation sites for reverse magnetic domains, they effectively reduce the intrinsic grain boundary magnetic strength, leading to a drop in the coercivity. We concluded that the sintered SmCo5 magnets could be recycled with up to 2 wt.% Ni/Cu as a residual from the coating under our sintering and heat treatment conditions.

High-Performance Anisotropic Nanocomposites with a Novel Core/shell Microstructure.

Anisotropic nanostructures of magnetically hard and soft materials are fascinating for exploring next-generation ultrastrong permanent magnets with less expensive rare-earth elements. It is a big challenge fabricating high-performance nanocomposites due to the difficulty in controlling the grain size of the soft phase. Here, surfactant-assisted low-temperature chemical coating (LTCC) is adopted to fabricate SmCo5@FeCo nanocomposites. A uniform coating layer of the soft phase ranging from 5 to 15 nm FeCo particles is obtained. Both high coercivity Hc of 17.2 kOe and high energy product (BH)max of 29.4 MGOe in the optimal anisotropic SmCo5@FeCo nanocomposites with 15 wt % soft phase coating had been successfully fabricated, which has an enhancement of 31% compared with that of the uncoated single SmCo5 phase. The excellent performance is ascribed to nanosized grains of both soft and hard phases and a high remanence ratio Mr/Ms of 0.976. These results made a big step toward synthesizing a stronger bulk nanocomposite system.

Epitaxy Induced Highly Ordered Sm2Co17-SmCo5 Nanoscale Thin-Film Magnets.

Utilizing the molecular beam epitaxy technique, a nanoscale thin-film magnet of c-axis-oriented Sm2Co17 and SmCo5 phases is stabilized. While typically in the prototype Sm(Co, Fe, Cu, Zr)7.5-8 pinning-type magnets, an ordered nanocomposite is formed by complex thermal treatments, here, a one-step approach to induce controlled phase separation in a binary Sm-Co system is shown. A detailed analysis of the extended X-ray absorption fine structure confirmed the coexistence of Sm2Co17 and SmCo5 phases with 65% Sm2Co17 and 35% SmCo5. The SmCo5 phase is stabilized directly on an Al2O3 substrate up to a thickness of 4 nm followed by a matrix of Sm2Co17 intermixed with SmCo5. This structural transition takes place through coherent atomic layers, as revealed by scanning transmission electron microscopy. Highly crystalline growth of well-aligned Sm2Co17 and SmCo5 phases with coherent interfaces result in strong exchange interaction, leading to enhanced magnetization and magnetic coupling. The arrangement of Sm2Co17 and SmCo5 phases at the nanoscale is reflected in the observed magnetocrystalline anisotropy and coercivity. As next-generation permanent magnets require designing of materials at an atomic level, this work enhances our understanding of self-assembling and functioning of nanophased magnets and contributes to establishing new concepts to engineer the microstructure for beyond state-of-the-art magnets.

Tip Interface Exchange-Coupling Based on "Bi-Anisotropic" Nanocomposites with Low Rare-Earth Content.

Specially designed SmCo5/Co magnetic nanocomposites have been fabricated by a "bottom up" process. SmCo5 nanochips were first prepared by solution-phase chemical synthesis combined with reductive annealing and then coated by chemical deposition of Co nanorods. Both the SmCo5 nanochips and Co nanorods are anisotropic and could be simultaneously aligned under the external magnetic field. Magnetic measurements applied on these "bi-anisotropic" SmCo5/Co composites show high magnetic performance with the Co phase content in a wide range from 10 to 80 wt %. For the first time ever, the applicable exchange-coupled nanocomposites with a rare-earth content lower than 7 wt % was realized, which exhibits the coercivity close to 10 kOe and remanence 31% larger than that of single phase SmCo5. 3-D micromagnetic simulations were performed to reveal that the reversal mechanism in the Co phase was transferred from the incoherent mode to the coherent mode under a tip interface exchange-coupling with a SmCo5 surface.