Microstructure and magnetic properties of MnBi alloys with high coercivity and significant anisotropy prepared by surfactant assisted ball milling

•MnBi bonded magnets with the (BH)max of 9.06 MGOe was obtained at room temperature.•Fine grain size and enhanced magnetic isolation effects contribute to high coercivity.•Magnetic hardening mechanism can be well explained by the strong pinning model. MnBi alloys with high content of low temperature phase (LTP) MnBi and excellent magnetic properties were prepared by surfactant assistant ball milling (SABM), using annealed ribbons as precursors. Effects of the SABM processes on the phase constituent, microstructure, and magnetic properties were investigated in detail. It is found that the reduction of saturation magnetization is mainly attribute to the decomposition of LTP MnBi into Mn phase, Bi phase and MnO phase, with increasing the ball milling time. Meanwhile, due to the fine grain size and increased magnetic isolation effects between LTP MnBi grains, the coercivity increases monotonously with prolonging the ball milling time to 10 h for Mn55Bi45 powders. Through compression molding under the magnetic field, based on the SABM powders, the optimum anisotropic bonded magnet displays the maximum energy product (BH)max of 9.06 MGOe at room temperature, and a value of 7.05 MGOe at 380 K can be still achieved. In addition, the magnetic hardening mechanism of bonded magnets can be well explained by the strong pinning model. Strongly favorable magnetic properties make bonded MnBi magnets an attractive candidate material for small permanent magnets used for temperature applications up to 380 K.