Effects of Ni and Cu Residuals on the Magnetic Properties and Microstructure of SmCo(5) Magnets

The effect of Ni/Cu-coating residuals on the magnetic properties and microstructures of samarium–cobalt (SmCo(5)) magnets was studied. SmCo(5) magnets with 0.0, 0.5, 1.0, 2.0, 3.0 and 4.0 wt.% of added Ni/Cu (85 wt.% Ni/15 wt.% Cu) were prepared using a conventional sintering route. The magnetic properties of the magnets were found to be consistent up to 2 wt.% Ni/Cu. Any further increase in the Ni/Cu content resulted in a significant reduction in the magnetic properties, to lower than values that would be commercially acceptable. SEM/EDS studies showed that two major phases, i.e., the SmCo(5) matrix phase and Sm(2)O(3) were present in all the sintered SmCo(5) magnets. The presence of Sm(2)Co(7) as a minor phase fraction was detected in the sintered SmCo(5) magnets containing up to 2 wt.% Ni/Cu. A 2 wt.% Ni/Cu addition to magnets resulted in the presence of two new phases with compositions close to SmCo and Sm(2)Co(17) in addition to SmCo(5) and Sm(2)O(3) as major phases in the SEM-observed microstructure. These newly formed phases are present in small fractions and are presumably homogenously distributed at the grain boundaries of the magnets. As they are known to act as nucleation sites for reverse magnetic domains, they effectively reduce the intrinsic grain boundary magnetic strength, leading to a drop in the coercivity. We concluded that the sintered SmCo(5) magnets could be recycled with up to 2 wt.% Ni/Cu as a residual from the coating under our sintering and heat treatment conditions.