Concurrent improvements of corrosion resistance and coercivity in Nd-Ce-Fe-B sintered magnets through engineering the intergranular phase

Usually the improved coercivity of rare earth (RE) based 2:14:1-type permanent magnets via RE-rich intergranular additives is achieved at the cost of more corrosion channels and deteriorated corrosion resistance, which remains a challenging hurdle in the RE-Fe-B community. Distinctly, here we report the concurrent improvements of corrosion resistance and coercivity in 40 wt.% Ce-substituted Nd-Ce-Fe-B sintered magnets through engineering the intergranular phase using simple (Nd, Pr)Hx additive. The dehydrogenated Nd/Pr changes the RE concentration gradients between 2:14:1 matrix and intergranular phases during sintering and enlarges the fraction of corrosion-resistant REFe2 phase, rather than the conventionally assumed Nd/Pr-rich intergranular phase with high chemical vulnerability. The spontaneous formation of REFe2 intergranular phase after (Nd, Pr)Hx addition generates the uniquely enhanced corrosion resistance against the hot/humid and acidic environments, and counts as one peculiar feature of Nd-Ce-Fe-B magnets at high Ce substitution level, being distinct from previously reported Ce-free/lean RE-Fe-B. Simultaneously, the formation of continuous grain boundaries enhances the coercivity from 8.7 to 12.5 kOe with trace addition of (Nd, Pr)Hx. Above findings may spur progress towards developing a high-performance Nd-Ce-Fe-B permanent magnet.