This study examines the distribution of heavy rare-earth elements (HRE) and magnetic properties in sintered NdFeB permanent magnets treated with Dy vacuum evaporation grain boundary diffusion, considering variations in time and temperature. The HRE distribution and magnetic properties were analyzed using an electron probe microanalyzer (EPMA), glow discharge optical emission spectrometer (GDOES), and hysteresis loop meter. The optimal temperature gradient for achieving the best results was found to be between 850 °C and 950 °C for a duration of 10 h. This resulted in iHc of 1415 kJ/m and (BH)max of 396.2 kJ/m3, which is classified as N52H grade. In comparison, the untreated NdFeB magnets had iHc of 1105 kJ/m and (BH)max of 400.3 kJ/m3, classified as N52 M grade. The results suggest that 0.167 wt% consumption of vacuum evaporated Dy alloy can enhance the 28 % in iHc of the magnet and 5 % increase in (BH)max compared to the untreated ones. This innovative manufacturing method improves the utilization of rare heavy earth and enhances the overall magnetic properties. This material has the potential to be used in the development of low-weight rare earth-sintered NdFeB magnets with high intrinsic coercivity. This study's findings advance energy-efficient technologies such as electric vehicles and offshore wind turbines, aiding global energy conservation efforts.
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