Blending Powder Process for Recycling Sintered Nd-Fe-B Magnets

The wide application of Nd-Fe-B permanent magnets, in addition to rare-earth metal resource constraints, creates the necessity of the development of efficient technologies for recycling sintered Nd-Fe-B permanent magnets. In the present study, a magnet-to-magnet recycling process is considered. As starting materials, magnets of different grades were used, which were processed by hydrogen decrepitation and blending the powder with NdH(x). Composition inhomogeneity in the Nd(2)Fe(14)B-based magnetic phase grains in the recycled magnets and the existence of a core-shell structure consisting of a Nd-rich (Dy-depleted) core and Nd-depleted (Dy-enriched) shell are demonstrated. The formation of this structure results from the grain boundary diffusion process of Dy that occurs during the sintering of magnets prepared from a mixture of Dy-free (N42) and Dy-containing magnets. The increase in the coercive force of the N42 magnet was shown to be 52%. The simultaneous retention of the remanence, and even its increase, were observed and explained by the improved isolation of the main magnetic phase grains as well as their alignment.