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In-situ thermo-mechano-chemical transformation and consolidation of Sm-Co powders via a single-step route for bulk magnet fabrication

Author

Listed:
  • Aniruddha Malakar

    (North Carolina State University
    Pacific Northwest National Laboratory)

  • Andrew Martin

    (North Carolina State University)

  • Farhan Ishrak

    (North Carolina State University)

  • Caleb Schenck

    (North Carolina State University)

  • Anqi Yu

    (Pacific Northwest National Laboratory)

  • Mayur Pole

    (Pacific Northwest National Laboratory)

  • Jens Darsell

    (Pacific Northwest National Laboratory)

  • Tianhao Wang

    (Pacific Northwest National Laboratory)

  • Joseph Helsing

    (Stevens Institute of Technology)

  • John Thornton

    (AFM Unit)

  • Michael Lastovich

    (North Carolina State University)

  • Libor Kovarik

    (Pacific Northwest National Laboratory)

  • Glenn Grant

    (Pacific Northwest National Laboratory)

  • Joseph B. Tracy

    (North Carolina State University)

  • Martin Thuo

    (North Carolina State University)

  • Mert Efe

    (Pacific Northwest National Laboratory)

  • Bharat Gwalani

    (North Carolina State University)

Abstract

The demand for high-performance permanent magnets continues to grow across a wide range of advanced technologies. However, conventional powder metallurgy routes for rare-earth magnets such as Sm–Co are limited by the intrinsic brittleness of the powders, reducing manufacturability and yield. Here, we report a single-step, solid-state processing method—friction consolidation (FC)—that enables simultaneous deformation, heating, and chemical transformation of brittle Sm–Co powders. Using commercial SmCo₅ powders containing Sm₂Co₇, FC induces a thermo-mechano-chemical pathway in which Sm₂Co₇ undergoes oxidation to form nanoscale SmCo(5–x) (where x

Suggested Citation

  • Aniruddha Malakar & Andrew Martin & Farhan Ishrak & Caleb Schenck & Anqi Yu & Mayur Pole & Jens Darsell & Tianhao Wang & Joseph Helsing & John Thornton & Michael Lastovich & Libor Kovarik & Glenn Gran, 2025. "In-situ thermo-mechano-chemical transformation and consolidation of Sm-Co powders via a single-step route for bulk magnet fabrication," Nature Communications, Nature, vol. 16(1), pages 1-12, December.
    • Handle: RePEc:nat:natcom:v:16:y:2025:i:1:d:10.1038_s41467-025-62804-9
    DOI: 10.1038/s41467-025-62804-9
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    References listed on IDEAS

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    1. Tianhao Wang & Xiao Li & Zehao Li & Tingkun Liu & Xiang Wang & Arun Devaraj & Cindy A. Powell & Jorge F. Santos, 2024. "Upcycled high-strength aluminum alloys from scrap through solid-phase alloying," Nature Communications, Nature, vol. 15(1), pages 1-8, December.
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