The world is progressively shifting from a fossil-fuel-based energy-and-transportation system to more environmentally friendly and energy-efficient technologies. The transport sector currently presents a quarter of Europe's CO2 emissions. The European "Green Deal", presented in December 2019, aims at reaching net-zero greenhouse gas emissions by 2050. The emergence of electric vehicles and electricity production from renewable sources like wind power are necessary steps towards resolving contemporary environmental issues like climatic changes and air pollution in larger cities. However, the state-of-the-art traction motors and wind turbine generators often depend on Nd-Fe-B magnets to provide the strong and constant magnetic fields required to convert electrical to mechanical energy and vice versa. The rapid growth of the market for electric vehicles and advancements in green technologies development are inevitably related to the increasing demand for Nd and other rare-earth (RE) elements (RE = Nd, Pr, Dy, Tb). The rare-earth elements are considered most critical for Europe due to the high supply risk and their impact on the economy. Less than 1 % of all magnets are recycled after the magnet-containing device has been put out of use. It is thus necessary to develop cost-effective and sustainable reprocessing routes for end-of-life (EOL) permanent magnets. The hydrogen decrepitation (HD) of sintered magnets, combined with jet-milling, is used to obtain anisotropic Nd-Fe-B powders for further processing [1]. However, each reprocessing step exposes the material to oxidation, limiting its potential for the processing of high-coercivity magnets. Moreover, an increase in the oxygen content reduces the amount of the secondary Nd-rich phases, which can hinder the densification and evolution of microstructure during sintering when conventional powder metallurgy approaches are considered. Spark-plasma sintering (SPS) is a pulsed-current-activated, pressure-assisted sintering technique characterised by fast sintering kinetics. The technique exploits the Joule heating effect to consolidate a powder compact under non-equilibrium conditions. SPS offers a high potential for the net-shape manufacture of dense sintered bodies from various materials [2]. Recently, an SPS route was provided as an alternative to the conventional sintering of Nd-Fe-B jet-milled powders. By exploiting the SPS-specific sintering mechanisms, it is possible to densify such material without risking extensive grain growth or oxidation [3]. We have taken the spark-plasma sintering approach to synthesise anisotropic, fully-dense magnets from a heavily-oxidised Nd-Fe-B jet-milled powder. The powder that could not be sintered by conventional methods was obtained through hydrogen decrepitation and jet-milling of a magnet scrap and contained 0.8 wt.% of oxygen. Small additions of Nd-Cu eutectic alloy (up to 5 wt.%) were beneficial for developing the hard-magnetic properties in bulk magnets. We studied the effect of the sintering parameters such as heating rate and dwell time on magnetic properties and microstructure formation. The as-sintered samples' intrinsic coercivity exceeded 1000 kA/m, and the properties could be further tuned with post-sinter annealing.

**References:**

[1] A. Walton, H. Yi and N. A. Rowson, Journal of Cleaner Production, Vol. 104, p.236-241 (2015) [2] O. Guillon, J. Gonzalez Julian and B. Dargatz, Advanced Engineering Materials, Vol. 16, p.830-849 (2014) [3] T. Tomše, Z. Samardzija and L. Scherf, Journal of Magnetism and Magnetic Materials, Vol. 520, p.166504 (2020)

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 Anisotropic Nd-Fe-B Magnets Prepared from Recycled Jet-Milled Powders with Spark-Plasma Sintering Technique

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