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New alnico magnets fabricated from pre-alloyed gas atomization powder through diverse consolidation techniques

Recent concern for supply and price of rare earth (RE) metals has stimulated the search for alternative magnets [1]. Alnico is an attractive non-RE magnet alloy due to its excellent magnetic stability. However, the best energy product (BH)max of the magnets is only about 10 MGOe. A key to improving the magnetic properties is to enhance coercivity Hci by optimizing composition and microstructure [2]. While our efforts focus on how to improve the magnetic properties, new fabrication technologies of bulk alnico magnets are widely studied as well. In this study, fine spherical powder produced by gas atomization (GA) was consolidated through Hot Pressing (HP), Hot Isostatic Pressing (HIP), and Compression Molding and subsequently Sintering (CMS) techniques. The effects of different fabrication techniques and processing parameters on microstructure and magnetic properties were studied and discussed.