CaO-matrix processing of MnBi alloys for permanent magnets

The possibility to suppress agglomeration of MnBi alloy particles during milling and their unwanted sintering during subsequent annealing was explored by embedding the particles in CaO through co-milling. A 15 h annealing of the micron-sized MnBi particles embedded in the CaO matrix at 300 °C is not accompanied by sintering or growth of the particles while it significantly increases their coercivity – presumably by healing the milling-induced crystal defects. After separation from the CaO matrix, the annealed MnBi powder combines a calculated energy product of 10 MGOe with a room-temperature coercivity of 14.4 kOe. At the same time, the partial loss and degradation of the MnBi low-temperature phase during warm compaction of the powders makes the effect of the CaO-matrix annealing less pronounced in the case of fully dense magnets; the residue from the solvents employed for the removal of the CaO might have contributed to the decline of the properties. Still, a relatively high room-temperature coercivity of 8.5 kOe was obtained for the fuslly-dense MnBi magnet exhibiting an energy product of 5.3 MGOe.