Block Magnets with Uniform Core–Shell Microstructure Regenerated from NdFeB Grain Boundary Diffusion Sheet Magnets

The grain boundary diffusion (GBD) process is currently the relatively effective method for utilizing heavy rare earth (HRE) elements in NdFeB magnets, especially for magnetic sheets. However, due to a highly uneven microstructure, the recovery of GBD magnets was considered difficult. In this work, our study prioritized short-loop recycling of GBD NdFeB sheet magnets to prepare block magnets. A comparative investigation was conducted between GBD-processed NdFeB magnets and the conventional sintered magnets, with particular emphasis on their recyclability characteristics. Among them, the Tb content of GBD magnets of 0.4 wt.% was significantly lower than sintered magnets of 1.73 wt.%. When two waste magnets were supplemented with the same amount of rare earth, it was found that the coercivity of the block magnets regenerated from GBD sheet magnets was higher. Microstructural analysis revealed that the core-shell grains originally located in the surface layer of GBD magnets were uniformly mixed and diffused with the ordinary particles originally located inside during the regeneration sintering process. The regenerated GBD magnets exhibited a more uniform core-shell microstructure with submicron shells of Tb elements along with reduced areas of RE-rich phase enrichment which facilitated the formation of a continuous and uniform thin-layer grain boundary, thereby enhancing the magnetic isolation effect. Apart from the significance of recycling, these block magnets regenerated from GBD magnets also provides a new approach to solving the challenge of high coercivity and low HRE elements in bulk magnets.