Abstract
Traditional techniques for consolidating melt spun RE–Fe–B powders tend to incur significant volumes of non-magnetic material, like porosity and the polymer binder. Several alternative consolidation techniques are being studied in an effort to reduce the non-magnetic component and improve the overall performance of such magnets. Rapid electric discharge sintering (REDS) offers one method of fully densifying melt spun RE–Fe–B flakes in a rapid and efficient way with minimal material wastage. This paper attempted to consolidate stoichiometric RE2Fe14B, RE-lean and RE-rich compositions with REDS, spark plasma sintering and conventional hot-tool techniques. The relative magnetic performance and physical condition of the samples are compared. The success of a consolidation technique depends on the melt spun RE–Fe–B chemistry, the relative density of the final compact, and the ability to avoid excessive grain growth in the magnet microstructure.
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