Improvement of corrosion resistance and magnetic properties of Nd–Fe–B sintered magnets by Al85Cu15 intergranular addition

To improve the corrosion resistance and magnetic properties, Al85Cu15 (at.%) compound powders were added to (Pr, Nd)14.8Fe78.7B6.5 sintered magnets as grain boundary modifiers. The corrosion resistance was found to be remarkably improved by small additions of Al85Cu15 powders. When 1.2 wt% Al85Cu15 was added, the corrosion rate of magnets in humid environments was reduced by two orders of magnitude. This is partly due to the stability enhancement of the (Pr, Nd)-rich intergranular phase by Cu and Al. In addition, the occurrence of the Cu-rich phase ((Pr, Nd)22Fe56Cu10Al2O10), whose open-circuit potential is higher than the (Pr, Nd)-rich intergranular phase, may be another reason for the improvement of the corrosion resistance. Furthermore, the magnetic properties of (Pr, Nd)14.8Fe78.7B6.5 were also improved by adding 0.3–1.2 wt% Al85Cu15. Optimum addition amount was 0.6 wt%. The improvement of the magnetic properties may be related to the microstructural modification and the increase of magnet density.