Isotropic rare earth based hard magnets through non-equilibrium processing

The aim of this thesis was to understand better the relationship of hard magnetic properties to the microstructure and use this knowledge to design a better magnet.;The first project was focused on the development of isotropic Pr 9Fe85B6 ribbons with enhanced remanence, high coercivity and high (BH)max. The optimization was achieved by adjusting the composition, controlling the microstructure and processing parameters. The crystal structure in all the samples studied was found to consist of a fine mixture of hard phase 2:14:1 and soft alpha-Fe phase. In all the samples the optimum (BH)max obtained was in the optimally quenched ribbons. Annealing did improve the magnetic properties but did not exceed the highest (BH)max value obtained in the optimally quenched ribbons. Small additions of Tb and Co were found to improve the magnetic properties. The properties were optimized by first adjusting the wheel speed and then the ejection temperature of melt. A maximum (BH)max 21 MGOe and a remanence of 117 emu/g were obtained in the ribbons spun at 18 m/s and ejected at a temperature of 1360°C with a average grain size of 20 nm. This investigation suggests that a proper combination of composition and processing parameters is essential for the optimum (BH)max value for the Pr-Fe-B magnets.;The second project was focused on the development of a single phase nanocrystalline Sm2(Co, Fe)17 magnets. The magnetic properties such as coercivity and energy product were optimized via the design of composition, control of melt-spinning parameters and heat treatment. The effect of non magnetic elements like Si, B, addition on the Sm(Co, Fe, M)z alloys were investigated. The effect of C addition on the Smx(Co 1-yMy)100-x-zCz series alloys where, M= Fe or Fe+Mn, X=10-15, Y= 0-0.375, Z= 0-6 were studied thoroughly. It is observed that the crystal structure of Sm(Co0.75Fe0.25 )7, Sm(Co0.65Fe0.25Si0.1) 7 and Sm(Co0.65Fe0.25Si0.05B0.05 )8 alloy ribbons spun at low wheel speed shows the presence of 1:5 and 2:17 phase and the metastable 1:7 phase for high wheel speed. It is observed that C suppressed the formation of the stable 2:17 structure in favor of the disordered 1:7 phase. Addition of Si and B, C leads to the development of equiaxed finer grains. C may have act as grain growth inhibitor in the Sm-(Co-Fe)- C ribbons Microstructure refinement with the precipitation of RCoC2 carbides was observed in the C added ribbons. The carbon addition enhances the overall magnetic properties.;The 3rd project was focused on the investigation of giant intrinsic magnetic hardness in Sm(Co0.45,Fe0.15,Cu0.4) 5 alloys and determine its dependence on grain / particle size. Melt-spinning and high energy ball milling was used to prepare sample with different grain size (6-500 nm). A single phase 1:5 structure was observed in both the ribbons and milled powders of the Sm(Co0.45,Fe0.15,Cu0.4 )5 alloy. The maximum coercivity obtained was 21 kOe for ribbons spun at 50 m/s (70 nm) and 15 kOe for the powders milled for 15 min (15 nm). Low temperature annealing of ribbons with large grain size > 500 nm for 133 h increases the coercivity to 44 kOe similar like bulk. The effect of low temperature annealing of ribbons with the coarse grain structure (> 70 nm) was the increasing of coercivity, it also increased the Curie temperature of 1: 5 phase and resistivity. The effect of low temperature annealing on the coercivity of high energy milled powders with a smaller grain size (< 70 nm) was different from the ribbons. The maximum coercivity of 21 kOe was obtained for 3h milled powders annealed at 400°C for 1 h. However, after longer annealing the coercivity decreases and this is different behavior from bulk. The effect of annealing on the homogenized crushed powders (>140nm) was more like bulk, even after annealing for 50 h at 400°C coercivity obtained was 38.48 kOe and increasing. (Abstract shortened by UMI.).