Magnetic field control of microstructural development in melt-spun Pr2Co14B

In the processing of commercial rare earth permanent magnets, use of external magnetic fields is limited mainly to the alignment of anisotropic particles and the polarization of the finished magnets. Here we explore the effects of high magnetic fields on earlier stages of magnet synthesis, including the crystallization and chemical phase transformations that produce the 2:14:1 phase in the Pr-Co-B system. Pr2Co14B alloys produced by melt-spinning were annealed in the presence of strong applied magnetic fields (H=90 kOe). The resulting materials were characterized by x-ray diffraction, electron microscopy, and magnetization measurements. We find that magnetic fields suppress the nucleation and growth of crystalline phases, resulting in significantly smaller particle sizes. In addition, magnetic fields applied during processing strongly affects chemical phase selection, suppressing the formation of Pr2Co14B and α-Co in favor of Pr2Co17. The results demonstrate that increased control over key microstructural properties is achievable by including a strong magnetic field as a processing parameter for rare-earth magnet materials.