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Directional growth effect on magneto-mechanical properties of Fe81Al19 alloy is studied. The ideal model of heat flux for directional solidification (DS) technique is proposed, and the tuned A/L (the ratio of cross-sectional area and length for the ingot) and ΔT (temperature difference) are adopted to increase heat flux (q). The experimental result shows that the increase of q effectively promotes the degree of (011)[100] Goss texture and therefore helps to form an oriented stripe domain structure. Large λ100 of 93.8 ppm attained for this optimized Fe81Al19 alloy prepared by DS method is very close to that of the Fe81Al19 single crystal (95.0 ppm). For the optimized DS prepared Fe81Al19 alloy, high magnetostriction sensitivity (dλ/dH) of 0.45 ppm/Oe leads to huge ΔEs/E0 of ∼10% and attractive ΔE/E0 of 8.2% at small H = 0.25 kOe. The above remarkable magneto-mechanical properties, low cost of Fe81Al19, and simple process of DS favor for applications. This work proposes an ideal model to emphasize the importance of heat flux in DS, and experimentally attains the remarkable magneto-mechanical properties for Fe81Al19 alloy prepared by DS. [ABSTRACT FROM AUTHOR]

Traditional NdFeB sintered magnets with coercivity larger than 20 kOe, called super-high (SH) level, usually contains considerable amount of high-cost heavy rare earth (HRE), such as Dy or Tb. In this work, high coercivity of 21.4 kOe, which corresponds to SH level, is achieved for HRE-free NdFeB magnet by doping with Ce85Al15 (CeAl) alloy and grain boundary diffusion (GBD) with Pr70Cu15Al15 (PrCuAl) alloy powders, where Ce/RE ratio is about 15% within the magnet. After GBD treatment with PrCuAl on Ce-containing NdFeB magnets, the formation of Pr-containing shell at 2:14:1 grain surface can increase the local magnetic anisotropy filed and therefore enhance the coercivity. Most of Cu and Al, and parts of Ce and Pr appear at grain boundary and triple junction, which can reduce the magnetization of grain boundary phase, strengthen the decoupling effect between grains and thus contribute to high coercivity. This study provides a cost-effective way to obtain high coercivity for HRE-free NdFeB sintered magnet via doping Ce85Al15 and then GBD with Pr70Cu15Al15. [ABSTRACT FROM AUTHOR]

Traditional NdFeB sintered magnets with coercivity larger than 20 kOe, called super-high (SH) level, usually contains considerable amount of high-cost heavy rare earth (HRE), such as Dy or Tb. In this work, high coercivity of 21.4 kOe, which corresponds to SH level, is achieved for HRE-free NdFeB magnet by doping with Ce85Al15 (CeAl) alloy and grain boundary diffusion (GBD) with Pr70Cu15Al15 (PrCuAl) alloy powders, where Ce/RE ratio is about 15% within the magnet. After GBD treatment with PrCuAl on Ce-containing NdFeB magnets, the formation of Pr-containing shell at 2:14:1 grain surface can increase the local magnetic anisotropy filed and therefore enhance the coercivity. Most of Cu and Al, and parts of Ce and Pr appear at grain boundary and triple junction, which can reduce the magnetization of grain boundary phase, strengthen the decoupling effect between grains and thus contribute to high coercivity. This study provides a cost-effective way to obtain high coercivity for HRE-free NdFeB sintered magnet via doping Ce85Al15 and then GBD with Pr70Cu15Al15. [ABSTRACT FROM AUTHOR]