Abstract
Phase evolutions in Nd-Fe-B magnet/Cu systems have been explored with regard to Nd recycling. It was demonstrated that large scale phase separation into a ferromagnetic Fe(B)-rich ingot core with α-Fe main phase and a non-magnetic (Cu,Nd)-rich ingot rim takes place upon arc melting with Cu fractions ≥ 21.5 wt.-%. The re-solidification of the Nd2Fe14B magnet main phase is suppressed. The rim consists of the Cu2Nd main phase and CuNd/Cu4Nd minority phases in which Al traces from the magnetic material are gathered. Induction melting of such Nd-Fe-B/Cu mixtures can support the separation of these phase regions with very sharp boundaries. Main features of liquid phase separation and microstructure evolution have been interpreted on the basis of Nd-Fe-Cu phase diagram data. The key advantage with respect to Nd recycling from Nd-Fe-B permanent magnet scrap is the substantial accumulation of Nd in the (Cu,Nd)-rich region of the phase separated solidified specimen, which can be easily detached from the Fe-rich part by mechanical-magnetic treatments. Such portions contained up to ∼44 wt.-% Nd (25 at.-%) in first lab-scale experiments. Nd recovery from the (Cu,Nd)-rich fractions is possible by exploiting the large chemical property differences between the reactive rare earths elements and Cu.
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