LAUSR

Abstract Microstructures of Ga-doped ultra-fine-grained (UFG) Nd-Fe-B magnets processed from press-less sintering of He-jet-milled powder and hydrogenation-disproportionation-desorption-recombination (HDDR) powder have been investigated to understand the large coercivity difference in the two magnets with nearly the same grain size. While the sintered magnet processed from the jet-milled powder showed a very high coercivity of 2.14 T, the sintered magnet made from HDDR powder showed a low coercivity of only 1.31 T regardless of the similar grain size. Microstructure observations by scanning electron microscopy (SEM) and scanning transmission electron microscope (STEM) combined with energy-dispersive X-ray (EDS) analysis revealed that the Nd-rich grain boundary (GB) phase in the magnet produced from HDDR powder exhibits thickness of 1–2 nm with large variations in their chemical compositions, while the Nd-rich GB phase in the magnet made from He-jet-milled powder displays larger thickness variations (1–7 nm) along with significant increase of nonferromagnetic elements (Nd, Pr, Cu, Ga) in the GB phase after optimal annealing. The possible reasons for these differences in GB phases are discussed based on quantitative microstructure characterization results.