Development of High-Performance Hot-Deformed Neodymium–Iron–Boron Magnets without Heavy Rare-Earth Elements

Neodymium–iron–boron magnet is an essential material for the traction motors of green vehicles because it exhibits the highest maximum energy product, (BH)(max), out of all permanent-magnet materials. However, heavy rare-earth elements such as dysprosium and terbium, which are scarce resources, are added to these magnets to improve their heat resistance. To address this resource problem, considerable efforts have been made to reduce the composition of heavy rare-earth elements in these magnets without causing a significant reduction in coercivity. Hot-deformed Nd-Fe-B magnets are a category of Nd-Fe-B magnets where precious materials such as heavy rare-earth elements can be eliminated or reduced to maintain high coercivity owing to their fine microstructure. Although they are not often used for the fabrication of high-performance magnets due to their complicated production process and the difficulty in controlling their fine microstructure, after the rare-earth crisis in 2020, these magnets have begun to attract attention as a material that could increase coercivity when controlling their microstructures. This paper provides an overview of hot-deformed magnets and the efforts made to improve their properties by controlling their microstructures.