Nanocrystalline alternative rare earth-iron-boron permanent magnets without Nd, Pr, Tb and Dy: A review

Abstract

The continuous increase in the output of Nd-Fe-B permanent magnets leads to the increasing consumption of rare earth (RE) metals of Nd, Pr, Tb and Dy. As a result, a serious unbalanced utilization of RE resource occurs. To reduce the use of these critical REs, high abundance REs of Y, La, Ce and even Gd and Ho have been proposed to partly substitute Pr and Nd in sintered magnets and rapid-quenched nanocrystalline magnetic powders. Recently, the cost-effective RE-Fe-B magnets without Nd, Pr, Tb and Dy have also been developed. This type of magnet is preliminarily designed to bridge the magnetic properties gap between hard ferrites and bonded Nd-Fe-B magnets, which shows the potential applications in voice coil motor, spindle motors and magnetic resonance imaging systems. This review summarizes the progress of RE-Fe-B-type magnets containing no Nd, Pr, Dy and Tb based on the world-wide investigations and our recent findings. The fundamentals of intrinsic magnetic properties of Y, La, Ce based RE2Fe14B phases are introduced first. The relationship between magnetic properties and microstructure of rapidly quenched and bulk RE-Fe-B magnets with nanocrystalline structure is then emphatically discussed. Hard magnetic properties and performance/cost ratio of various RE-Fe-B alloy systems are summarized and compared. Furthermore, the current discoveries and the existing challenges are discussed. Some potential strategies for the future research in this field are finally proposed.