The effect of Cu-based core-sheath configurations on the processing of Nd-Fe-B-based permanent magnets via equal-channel angular pressing

Equal channel angular pressing (ECAP) has been used as an alternative manufacturing route for preparation of Nd₂Fe₁₄B-based anisotropic magnets, facilitating processing temperatures much lower than conventional die upsetting. While this method can produce a suitable texture and microstructure in permanent magnetic materials, it still remains novel; involving extremely high pressures which present a high risk of both process failure and die and tooling damage. Powder metallurgical processes frequently incorporate an external layer of secondary material (commonly an outer foil layer or can) for separation between the primary material and die as well as the control of surface effects such as friction through appropriate choice of secondary material. This work implements such modifications to this manufacturing route by incorporation of an outer layer of Cu foil, the addition of which negatively affected both the powder compaction and strength of texture produced via ECAP. Also investigated was the incorporation of solid Cu bar as part of the sample cross section. This modification facilitated processing without any compromise on observed magnetic properties, whilst also reducing damage to both the die and tooling. This type of methodology may aid in improving the reliability of producing bulk anisotropic permanent magnets via ECAP. (paper)