NdFeB Magnets with Well-Pronounced Anisotropic Magnetic Properties Made by Electric Current-Assisted Sintering

Electric current-assisted sintering (ECAS) technologies are highly promising for processing of NdFeB magnets. Due to the combination of direct Joule heating and application of external load, even powders, whose particle size distribution and morphology are not optimum for conventional powder processing like melt-spun powders or magnet scrap, can be easily sintered to high densities. A systematic study is done to demonstrate the potential of field-assisted sintering technique/spark plasma sintering (FAST/SPS) and flash spark plasma sintering (flash SPS) for sintering of NdFeB powders. Melt-spun, commercial NdFeB powder (Magnequench MQU-F) is used as starting material. Its platelet-like shape makes this powder extremely difficult to sinter by conventional methods. This study clearly reveals that especially in the case of flash SPS application of external pressure in combination with short cycle times enables to achieve well-pronounced anisotropic magnetic properties without the need of subsequent upset forging. Optimized flash SPS parameters are applied to NdFeB magnet scrap with broad particle size distribution, demonstrating the general potential of ECAS technologies for recycling of waste magnet materials. Finally, the results are benchmarked with respect to established NdFeB processing technologies and electrodischarge sintering (EDS), another promising ECAS technology with very short cycling time.

Automated summary

Electric current-assisted sintering technologies show great promise for processing NdFeB magnets, allowing for easy sintering of powders with suboptimal particle size distribution and morphology. Flash spark plasma sintering, especially when combined with external pressure, can achieve pronounced anisotropic magnetic properties. These ECAS technologies also have potential for recycling waste magnet materials and are compared to established processing technologies.