Magnetic and mechanical hardening of nano-lamellar magnets using thermo-magnetic fields

High-performance magnetic materials based on rare-earth intermetallic compounds are critical for energy conversion technologies. However, the high cost and supply risks of rare-earth elements necessitate the development of affordable alternatives. Another challenge lies in the inherent brittleness of current magnets, which limits their applications for high dynamic mechanical loading conditions during service and complex shape design during manufacturing towards high efficiency and sustainability. Here, we propose a strategy to simultaneously enhance the magnetic and mechanical performance of a rare-earth-free multicomponent magnet. We achieve this by introducing nano-lamellar structures with high shape anisotropy into a cobalt-iron-nickel-aluminum material system through eutectoid decomposition under externally applied thermo-magnetic fields. Compared to the conventional thermally activated processing, the thermo-magnetic field accelerates phase decomposition kinetics, producing finer lamellae spacings and smaller eutectoid colonies. The well-tailored size, density, interface, and chemistry of the nano-lamellae enhance their pinning effect against the motion of both magnetic domain walls and dislocations, resulting in concurrent gains in coercivity and mechanical strength. Our work demonstrates a rational pathway to designing multifunctional rare-earth-free magnets for energy conversion devices such as high-speed motors and generators operating under harsh service conditions.