Design and Qualification of Pr–Fe–Cu–B Alloys for the Additive Manufacturing of Permanent Magnets

Abstract The direct use of an advanced binder‐free additive manufacturing technique, namely laser powder bed fusion (L‐PBF), does not easily allow obtaining variously shaped, fully dense Nd–Fe–B magnets with high coercivity. The process inherently leads to the re‐melting of the powder and appearance/disappearance of undesired/desired microstructural features responsible for low and large coercivity. In this work, the development of a useful microstructure responsible for high coercivity in Pr₂₁Fe_73.5Cu₂B_3.5 and Nd₂₁Fe_73.5Cu₂B_3.5 alloys and a possible way to produce fully dense permanent magnets via additive manufacturing processes is demonstrated using: (i) suction casting technique, which provides a high cooling rate and thus similar microstructures as in L‐PBF but requires only very small amounts of powder; (ii) conventional L‐PBF processing using kg of powder, and (iii) a subsequent annealing treatment that is similar to a conventional sintering treatment. The subsequent heat treatment is necessary to develop high coercivity by forming a novel microstructure: hard magnetic (Nd,Pr)₂Fe₁₄B grains embedded in a matrix of intermetallic (Nd,Pr)₆Fe₁₃Cu phase. Furthermore, it is demonstrated that Pr₂₁Fe_73.5Cu₂B_3.5 exhibits a higher coercivity than Nd₂₁Fe_73.5Cu₂B_3.5 because of a finer and more homogeneous grain size distribution of the Pr₂Fe₁₄B phase. The final L‐PBF printed Pr₂₁Fe_73.5Cu₂B_3.5 samples provide a coercivity of 0.75 T.