Spheroidization of Nd-Fe-B particles

Spherical powders are required for many advanced manufacturing techniques due to their inherent requirement of flowability, either within feed tubes or during powder spreading. As advanced manufacturing of magnets continues to develop, new production methods for feedstocks are also sought. Plasma spheroidization is a high-yield method to produce spherical Nd-Fe-B powders from irregularly shaped particles, with advantages including high throughput and a well-controlled size distribution. Highly spherical Nd-Fe-B powders with large scale production (i.e., kg) have been demonstrated using an inductively coupled thermal plasma system; however, the magnetic properties of the output powder display significant degradation. The coercivity was decreased from the initial 8 kOe (636 kA/m) of the as-received to 0.7 kOe (55 kA/m) for spheroidized powders. Microstructural investigation reveals 6% Nd depletion caused by the extreme temperatures of the plasma, leading to the formation of low-coercivity alpha-Fe and a subsequent decrease in energy product. Post-spheroidization heat treatments with Nd can partially mitigate the coercivity degradation, increasing to 1.7 kOe (135 kA/m), potentially offering a pathway toward spherical powders for a range of applications.