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Highlights • The improved magnetic properties of HDDR powders were obtained by optimizing the Nd-rich phase distribution of ingot powders. • The coercivity of HP magnets still could be improved with the addition of Pr-Cu eutectic alloys. • The effect of Pr-Cu addition on coercivity of Nd-Fe-B HDDR magnets was clarified. Abstract The effect on the Nd-rich phase distribution of the ingot for hydrogenation-disproportionation-desorption-recombination (HDDR) powders was studied. Coercivity of HDDR powders was elevated to 1.64 T by crushing the ingot into particles and annealing at 800 °C for 18 h. HDDR processed Nd-Fe-B powders blended with Pr-Cu powders and annealed at 580 °C for 3 h were hot-pressed to obtain fully dense magnets. The microstructure evolution in hot-pressed HDDR magnets proved the impact of Pr-Cu diffusion on coercivity that the coercivity of hot-pressed magnets was improved to 1.55 T significantly. Backscatter electron microscopy and transmission electron microscopy observations revealed that the variation in coercivity owing to the diffusion of Pr-Cu along the grain boundary with heat treatment. L-TEM images illustrated the thicker grain boundary layer can pin the motion of the domain wall more effectively, resulting in a higher coercivity in HP magnets. [ABSTRACT FROM AUTHOR]