Effects of Carbon Doping and Annealing Temperature on Magnetic MnAl Powders and MnAl Polymeric Composites

Process parameters leading to magnetic polymer composites, an essential ingredient in the additive manufacturing of rare-earth-free magnets, are investigated. The induction melting of manganese (Mn) and aluminum (Al), and subsequent annealing at 450, 500, or 550 °C for 20 min, gave rise to ferromagnetic τ–MnAl phase, as well as other phases. The nonmagnetic Al4C3 and oxide phases were then removed by the magnetic separation. Magnetic powders from the magnetic separation were incorporated in polylactic acid (PLA) matrix via a solution route. The remanent magnetization as high as 4.3 emu/g in the powder form was reduced to 2.3–2.6 emu/g in the composites. The reduction in coercivity was minimal, and the largest value of 814 Oe was obtained when the powder annealed at 450 °C was loaded in the composite. The phase composition and hence magnetic properties were even more sensitive to the carbon (C) doping. Interestingly, the addition of 3% C led to coercivity as high as 1445 Oe in MnAl–C powders without further annealing. The enhanced coercivity was attributed to the domain wall pinning by the AlMn3C phase, and magnetizations are likely increased by this phase.

Unconventional magnetization textures and domain-wall pinning in Sm–Co magnets

Some of the best-performing high-temperature magnets are Sm–Co-based alloys with a microstructure that comprises an $$\hbox {Sm}_2\hbox {Co}_{17}$$ Sm 2 Co 17 matrix and magnetically hard $$\hbox {SmCo}_5$$ SmCo 5 cell walls. This generates a dense domain-wall-pinning network that endows the material with remarkable magnetic hardness. A precise understanding of the coupling between magnetism and microstructure is essential for enhancing the performance of Sm–Co magnets, but experiments and theory have not yet converged to a unified model. Here, transmission electron microscopy, atom probe tomography, and nanometer-resolution off-axis electron holography have been combined with micromagnetic simulations to reveal that the magnetization state in Sm–Co magnets results from curling instabilities and domain-wall pinning effects at the intersections of phases with different magnetic hardness. Additionally, this study has found that topologically non-trivial magnetic domains separated by a complex network of domain walls play a key role in the magnetic state by acting as nucleation sites for magnetization reversal. These findings reveal previously hidden aspects of magnetism in Sm–Co magnets and, by identifying weak points in the microstructure, provide guidelines for improving these high-performance magnetic materials.