Decomposition of DyF3 and its effect on the magnetic performance of the hot-pressed compact and die-upset magnet of melt-spun Nd-Fe-B-type material were investigated. DyF3 was thermally decomposed above 660 °C, and this decomposition was linked closely to the coercivity enhancement. When the DyF3 doped flakes were hot-pressed above the decomposition temperature of DyF3, the diffusion of Dy into the flakes was promoted, and leading to profound coercivity enhancement. Coercivity of the hot-pressed magnet was further enhanced by post-hot-press annealing, and coercivity as high as 24.5 kOe was obtained after the optimum annealing. The DyF3 doped hot-deformed magnet exhibited enhanced magnetic performance (iHc = 17.5 kOe, Br = 12.8 kG, (BH)max = 37.6 MGOe) with respect to the un-doped magnet without sacrificing significant remanence. Coercivity was improved by 30%. In magnet in which the decomposition of DyF3 and Dy diffusion were fully accomplished, the region originally occupied by added DyF3 was completely replaced by NdF3.

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Nd-Fe-B-type die-upset magnet with high electrical resistivity was prepared by doping of eutectic DyF3–LiF salt mixture. Mixture of melt-spun Nd-Fe-B flakes (MQU-F: Nd13.6Fe73.6Co6.6Ga0.6B5.6) and eutectic binary (DyF3–LiF) salt (25 mol% DyF3 – 75 mol% LiF) was hot-pressed and then die-upset. By adding the eutectic salt mixture (> 4 wt%), electrical resistivity of the die-upset magnet was enhanced to over 400 μΩ.cm compared to 190 μΩ.cm of the un-doped magnet. Remarkable enhancement of the electrical resistivity was attributed to homogeneous and continuous coverage of the interface between flakes by the easily melted eutectic salt dielectric mixture. It was revealed that active substitution of the Nd atoms in neighboring flakes by the Dy atoms from the added (DyF3–LiF) salt mixture had occurred during such a quick thermal processing of hot-pressing and die-upsetting. This Dy substitution led to coercivity enhancement in the die-upset magnet doped with the eutectic (DyF3–LiF) salt mixture. Coercivity and remanence of the die-upset magnet doped with (DyF3–LiF) salt mixture was as good as those of the DyF3-doped magnet.

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