Nd-Fe-B Magnets: The Gradient Change of Microstructures and the Diffusion Principle after Grain Boundary Diffusion Process

The diffusion of Tb in sintered Nd-Fe-B magnets by the grain boundary diffusion process can significantly enhance coercivity. However, due to the influence of microstructures at different depths, the coercivity increment and temperature stability gradually decreases with the increase of diffusion depth, and exhibit good corrosion resistance at a sub-surface layer (300–1000 μm). According to the Electron Probe Micro-analyzer (EPMA) test results and the diffusion mechanism, the grain boundary and intragranular diffusion behavior under different Tb concentration gradients were analyzed, and the diffusion was divided into three stages. The first stage is located on the surface of the magnet, which formed a thick core-shell structure and a large number of RE-rich phases. The second stage is located in the sub-surface layer, forming a uniform and continuous RE-rich phase and thin core-shell structure. The third stage is located deeper in the magnet, and the Tb enrichment only existed at the triangular grain boundary.