Mechanochemical synthesis of magnetically hard anisotropic RFe10Si2 powders with R representing combinations of Sm, Ce and Zr

Alloy synthesis consisting of mechanical activation followed by annealing was explored as a method of manufacturing medium-grade permanent magnet materials with a reduced content of the critical rare earth elements. Four RxFe10Si2 alloys with R=Sm, Sm0.7Zr0.3, Sm(0.7)Ce(0.3)r(0.4) and Ce0.6Zr0.4 (nominal compositions) were prepared from mixtures of Sm2O3, CeO2, ZrO2, Fe2O3 and Si powders in the presence of a reducing agent Ca and a CaO dispersant. The collected alloy particles typically consisted of few joined submicron crystals. For R=Sm, X-ray diffraction analysis reveals a significant amount of the unwanted Th2Zn17-type compound forming alongside the desired ThMn12-type 1:12 compound. A more pure 1:12 phase could be obtained for R=Ce0.6Zr0.4, but it exhibited a room-temperature coercivity of less than 1 kOe. The most pure 1:12 phase and the highest values of the coercivity (10.8 kOe) and calculated maximum energy product (13.8 MGOe) were obtained for R=Smo7Zro3 processed at 1150 degrees C. The calculated maximum energy products of the Sm0.3Ce0.3Zr0.4Fe10Si2 particles, with half of their rare earths constituents represented by the relatively abundant Ce, was 10.1 MGOe. (C) 2016 Elsevier B.V. All rights reserved.