TbCu7-type Sm-Fe(-N) powder synthesized by low-temperature reduction-diffusion process using the Li-Ca reductant.

It was predicted that TbCu7-type Sm-Fe powder prepared by the low-temperature reduction-diffusion (LTRD) process using a Li-Ca reductant would contain no residual ɑ-Fe because this reductant would not produce the absorbed water that hinders the reaction between Sm and Fe by forming oxychlorides when molten salt is used as the reductant. Contrary to this expectation, a detailed microstructure analysis revealed that a residual phase of unreacted ɑ-Fe existed in some TbCu7-type Sm-Fe particles rather than as separate Fe particles. This residual ɑ-Fe phase was not located in the center of the Sm-Fe particles and was not detected in some Sm-Fe particles, suggesting that the reason for the residual ɑ-Fe phase is inhomogeneous diffusion of Sm into the Fe due to slow diffusion at low temperatures. Although this TbCu7-type Sm-Fe powder contained a small amount of unreacted ɑ-Fe phase, the magnetic properties of the nitride TbCu7-type Sm-Fe were also estimated.

Synthesis of mesoscopic particles of multi-component rare earth permanent magnet compounds.

Multielement rare earth (R)-transition metal (T) intermetallics are arguably the next generation of high-performance permanent magnetic materials for future applications in energy-saving and renewable energy technologies. Pseudobinary Sm2Fe17N3 and (R,Zr)(Fe,Co,Ti)12 (R = Nd, Sm) compounds have the highest potential to meet current demands for rare-earth-element-lean permanent magnets (PMs) with ultra-large energy product and operating temperatures up to 200°C. However, the synthesis of these materials, especially in the mesoscopic scale for maximizing the maximum energy product ( B H m a x ), remains a great challenge. Nonequilibrium processes are apparently used to overcome the phase-stabilization challenge in preparing the R-T intermetallics but have limited control of the material's microstructure. More radical bottom-up nanoparticle approaches based on chemical synthesis have also been explored, owing to their potential to achieve the desired composition, structure, size, and shape. While a great achievement has been made for the Sm2Fe17N3, progress in the synthesis of (R,Zr)(Fe,Co,Ti)12 magnetic mesoscopic particles (MMPs) and R-T/T exchange-coupled nanocomposites (NCMs) with substantial coercivity ( H c ) and remanence ( M r ) , respectively, remains marginal.