Hf-Co and Zr-Co alloys for rare-earth-free permanent magnets

The structural and magnetic properties of nanostructured Co-rich transition-metal alloys, Co100-xTMx (TM = Hf, Zr and 10 <= x <= 18), were investigated. The alloys were prepared under non-equilibrium conditions using cluster-deposition and/or melt-spinning methods. The high-anisotropy HfCo7 and Zr2Co11 structures were formed for a rather broad composition region as compared to the equilibrium bulk phase diagrams, and exhibit high Curie temperatures of above 750 K. The composition, crystal structure, particle size, and easy-axis distribution were precisely controlled to achieve a substantial coercivity and magnetization in the nanostructured alloys. This translates into high energy products in the range of about 4.3-12.6 MGOe, which are comparable to those of alnico.