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<p>It is still a key challenge to balance the controlling synthesis and scale-up preparation of Co-substituted Sm<sub>2</sub>Fe<sub>17</sub>N<sub>3</sub> powders to meet bonded magnets’ requirements. Herein, a reduction–diffusion technology assisted by KCl was developed to prepare kilogram-scale Sm<sub>2</sub>(Fe<sub>1-<i>x</i></sub>Co<sub><i>x</i></sub>)<sub>17</sub>N<sub>3</sub> (0 ≤ <i>x</i> ≤ 0.18) single-phase powders based on a custom-designed rotary furnace. The addition of KCl and employment of rotary annealing equipment could greatly improve the uniformity of phase and element distribution, even in kilogram-scale preparation. Attributed to the controllable Co substitution and the multiscale feature with powder size in the range of 0.3–3.0&#xa0;μm, the optimal magnetic properties are achieved in Sm<sub>2</sub>(Fe<sub>0.88</sub>Co<sub>0.12</sub>)<sub>17</sub>N<sub>3</sub>, with a coercivity of 1053.9&#xa0;kA·m<sup>−1</sup>, saturation magnetization of 118.84&#xa0;Am<sup>2</sup>·kg<sup>−1</sup>, and maximum energy product of 865.8&#xa0;kJ·m<sup>−3</sup>. Density functional theory calculations demonstrate that Co substitution modifies the electron density of Sm, leading to enhanced magnetic properties. This work provides both fundamental insights and a practical route for the scalable production of high-performance Sm<sub>2</sub>Fe<sub>17</sub>N<sub>3</sub> powders, accelerating their commercialization in bonded magnets.</p> Graphical abstract <p></p>

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A large-scale synthesis of Co atoms modulated Sm2Fe17N3 powders

  • 期刊论文

  • 发表日期：

    2025年9月22日

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  • Hang Xue,
  • Yu-Hao Yi,
  • Bo-Qian Jia,
  • Jia-Ying Chen,
  • Long-Long Dong,
  • You Xue,
  • Kai-Yun Chen,
  • Zhen-Hui Ma,
  • Dan-Yang Chen,
  • Jun-Jie Xu

摘要

It is still a key challenge to balance the controlling synthesis and scale-up preparation of Co-substituted Sm2Fe17N3 powders to meet bonded magnets’ requirements. Herein, a reduction–diffusion technology assisted by KCl was developed to prepare kilogram-scale Sm2(Fe1-xCox)17N3 (0 ≤ x ≤ 0.18) single-phase powders based on a custom-designed rotary furnace. The addition of KCl and employment of rotary annealing equipment could greatly improve the uniformity of phase and element distribution, even in kilogram-scale preparation. Attributed to the controllable Co substitution and the multiscale feature with powder size in the range of 0.3–3.0 μm, the optimal magnetic properties are achieved in Sm2(Fe0.88Co0.12)17N3, with a coercivity of 1053.9 kA·m−1, saturation magnetization of 118.84 Am2·kg−1, and maximum energy product of 865.8 kJ·m−3. Density functional theory calculations demonstrate that Co substitution modifies the electron density of Sm, leading to enhanced magnetic properties. This work provides both fundamental insights and a practical route for the scalable production of high-performance Sm2Fe17N3 powders, accelerating their commercialization in bonded magnets.

Graphical abstract