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Hadjipanayis, George C.

Publications and source records attributed to Hadjipanayis, George C..

13 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Intrinsic and hard magnetic properties of (Sm 1-x R x )-Fe-Co-V alloys (R = Gd, Zr, and Y)

SmFe 12 -based compounds with the ThMn 12 -type structure have a great potential as future rare-earth-lean permanent magnets. However, their reliance on stabilizing non-magnetic elements has impeded practical applications. Therefore, elements such as Gd, Y, and Zr have gained popularity as candidates to minimize the need for stabilizing elements by reducing the formation energy of the ThMn 12 (1:12) phase. Here, this study examines the effect of Gd, Y, and Zr on the intrinsic and hard magnetic properties in (Sm 1-x R x ) 1.2 Fe 8.4 Co 2.1 V 1.5 (or with nominal composition of (Sm 1-x R x ) 9.1 Fe 63.6 Co 15.9 V 11.4 ) with a single 1:12 phase for 0 ≤ x ≤ 0.3. Notably, samples substituted with Gd exhibit an enhanced temperature dependence of the magnetic properties.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Bulk magnetic hardening in Sm(Fe,V) 12 alloys

Cast Sm-Fe-V magnets with the tetragonal crystal structure of the ThMn 12 type were prepared with high coercivity through a two-step annealing at 775°C and then at 825°C. The annealing processing used allowed us for the first time to successfully produce a large amount of non-magnetic Sm-rich grain-boundary phase in Sm-Fe-V cast ingots. As a result, the sample with composition Sm 11.1 Fe 75.8 V 13.1 showed the record-high coercivity (6.66 kOe) after annealing at 775°C for 72 h and then 825°C for 2 h. Furthermore, this coercivity, achieved without the use of powder metallurgy, has nearly doubled compared to the previously reported highest value of 3.70 kOe in a cast SmFe 10 V 2 .

36 MATERIALS SCIENCE↗
DOE OSTI2023

Structural Characteristics and Phase Evolution of Calcium-Reduced (Sm,Zr)(Fe,Co,Ti) 12 Particles

Magnetic materials are essential for applications in electronics, energy conversion and many other industrial and technological sectors. Among the permanent magnets, rare-earth magnets exhibit the strongest properties and dominate the market shares in related applications. However, due to the increasing cost and unstable supply, the research on reducing the rare-earth elements in magnets attracts significant increasing interest. Rare-earth-lean samarium transition metal (TM) compounds (SmTM 12 or 1:12 for short) have made breakthroughs in 2020 and the (Sm,Zr)(Fe,Co,Ti) 12 monocrystalline particles synthesized by a Ca reduction of elemental oxides at high temperature demonstrated an order of magnitude improvement in coercivity at room temperature. In this study, we made structural analysis of (Sm,Zr)(Fe,Co,Ti) 12 particles to elucidate the impact of synthesis conditions, microstructure and phase transformation on the evolution of magnetic properties.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Phase equilibria in iron-rich Sm–Fe–Ti and Sm–(Fe,Co)–Ti alloys at 1100–1200 °C

Iron-rich corners of ternary Sm–Fe–Ti phase diagram at 1100 °C and quasi-ternary Sm–Fe 0.8 Co 0.2 –Ti phase diagrams at 1100 and 1200 °C are constructed based on experimental investigation of equilibrated alloys with electron probe microanalysis, X-ray diffraction and thermomagnetic analysis. In addition, the upper boundaries of the temperature ranges of Sm(Fe,[Co,]Ti) 12 and Sm 3 (Fe,[Co,]Ti) 29 phases are determined with differential thermal analysis to update earlier rough estimates. The existence of a high-temperature phase of the Th 2 Ni 17 type, originally reported by Ivanova et al. [J. Alloys Compd. 224 (1995) 29], is confirmed. In the Sm–Fe 0.8 Co 0.2 –Ti system, the composition and equilibria of this hexagonal phase are established for 1200 °C; it is Sm-depleted (≈9.8 at.% Sm) compared to the 2:17 stoichiometry and it coexists with the rhombohedral 2:17 phase. The magnetic anisotropy of the cobalt-substituted Th 2 Ni 17 -type phase is planar, with the easy magnetization direction parallel to [100]. Equilibrium between a Sm-rich liquid phase and the 1:12 phase, which is important for the development of new high-performance permanent magnets, is absent up to 1000 °C, but does exist at 1100 °C (for the 1:12 phase with at least 8.7–8.9 at.% Ti) and at 1200 °C (for the 1:12 phase with as little as 7.4 at.% Ti). The development of magnets may be complicated, however, by an observed tendency of the high-temperature liquid to solidify into ferromagnetic phases including the Th 2 Ni 17 -type phase. The Curie temperatures of the α-(Fe,Ti), Sm(Fe,Ti) 12 , Sm 3 (Fe,Ti) 29 and rhombohedral Sm 2 (Fe,Ti) 17 phases are not only increased by the partial Co substitution for Fe, but their dependence on the Ti concentration is changed by this Co substitution from positive (or, for the 1:12 phase, zero) to negative values.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Assessment of Directionally Solidified Eutectic Sm–Fe(Co)–Ti Alloys as Permanent Magnet Materials

Sm–Fe–Ti and Sm–Fe0.8Co0.2–Ti alloys were prepared via arc-melting and directionally solidified on a water-cooled copper hearth. The as-solidified alloys featured cells of the Sm(Fe,Co,Ti)12–Ti(Fe,Co) 2+δ –(α-Fe) lamellar eutectic. The lamellae of Sm(Fe,Co,Ti)12 phase with a crystal structure of the ThMn12 type were less than 0.2 μm thick, and had their [001] easy-magnetization directions oriented along the temperature gradient of the solidification. The eutectic microstructure led to an increased coercivity, especially in the Co-added alloys. Below 250 °C, this coercivity was found not to vary much with temperature with a temperature coefficient of -0.18 %/°C. However, the modest absolute values, reaching only 0.7 kOe, are insufficient for utilization of the directionally solidified alloys as anisotropic permanent magnets.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Re-investigation of high-temperature phase equilibria in Fe-rich Sm–Fe–Ti alloys

Recently renewed attempts to develop high-performance rare-earth-lean permanent magnets based on the Sm(Fe,Ti) 12 compound have drawn attention to the limited knowledge about the high-temperature phase equilibria in the Sm–Fe–Ti system. Experimental investigation of equilibrated alloys with electron probe microanalysis, X-ray diffraction and thermomagnetic analysis revealed several inaccuracies in the currently accepted phase relations at 1000°C and allowed for a revision of the Fe-rich corner of the Sm–Fe–Ti phase diagram. The Sm(Fe,Ti) 12 and Sm 3 (Fe,Ti) 29 phases were found to have more extended Ti ranges of 5.1–9.7 at% and 2.8–6.9 at%, respectively. With increasing of the Ti content, the Curie temperature of the Sm(Fe,Ti) 12 remains nearly constant at 306–312°C, whereas that of the Sm 3 (Fe,Ti) 29 increases from 188°C to 207°C. The low-titanium Sm 3 (Fe,Ti) 29 phase equilibrates not only with the Sm(Fe,Ti) 12 and Sm2(Fe,Ti) 17 phases, but also with (α-Fe) solid solution. Newly demonstrated equilibrium between Sm 2 (Fe,Ti) 17 and TiFe 2 phases makes impossible the earlier reported equilibrium between the Sm 3 (Fe,Ti) 29 and Sm(Fe,Ti) 11 phases. Because of an invariant reaction at 1000 °C, the revised phase diagram also features a class II four-phase equilibrium Sm 3 (Fe,Ti) 29 + TiFe 2 + Sm(Fe,Ti) 12 + Sm 2 (Fe,Ti) 17 . Peritectic decomposition of the Sm(Fe,Ti) 11 phase, which occurs either at 1075°C or at 1087°C, was found to have among its products the Sm(Fe,Ti) 12 phase. Although no such equilibration was attempted, it must be possible to obtain above 1087°C a two-phase state composed of the Sm(Fe,Ti) 12 phase and a liquid – which is important for manufacturing of the Sm(Fe,Ti) 12 - based permanent magnets via the liquid-phase sintering.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Effect of alloying with Sc, Nb and Zr on reduction-diffusion synthesis of magnetically hard Sm(Fe,Co,Ti) 12 -based monocrystalline powders

Powders of Sm(Fe,Co) 11.2 Ti 0.8 alloys modified with Sc, Nb and Zr, as well as with additional Ti were prepared by reducing mechanically activated raw oxides with Ca metal in the furnace preheated to 990–1250 °C. Expansion of the crystal lattice upon introduction of Nb or additional Ti implies that atoms of these elements replace the smaller Fe atoms in the tetragonal ThMn 12 -type structure. On the other hand, contraction of the lattice upon introduction of Sc or Zr was smaller than what was expected for replacement of the Sm atoms, which suggests that the Sc and Zr atoms replace both the Sm and Fe atoms. Washing away the reduction byproducts expands the crystal lattice of the 1:12 particles and increases their coercivity. The lattice expansion associated with the washing is believed to be caused by interstitial H atoms; more research, however, is needed to establish the mechanism(s) of the washing effect on the coercivity. The earlier reported development of a high coercivity in zirconium-modified monocrystalline particles achieved by increasing the reduction annealing temperature to ≈1200 °C was similarly characteristic of the particles modified with Sc (the coercivity reaches 11.5 kOe) and Nb (8.1 kOe), but not for the particles prepared with additional Ti where the maximum coercivity of 8.3 kOe develops for a lower annealing temperature. Furthermore, it is concluded that Sc, Nb and Zr modify the high-temperature phase equilibria of the Sm(Fe,Co) 11.2 Ti 0.8 alloys allowing for an effective high-temperature processing, whereas the alloy coercivity increases with the synthesis temperature through a different, still unknown mechanism which may involve suppression of the defects specific to the 1:12 crystals.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Microstructure and Hard Magnetic Properties of Sm 1-x Zr x (Fe,Co) 11.3-y Ti 0.7 By Ingots and Thick Melt-Spun Ribbons

Permanent magnets made from Sm(Fe,Co) 12 -based compounds are being actively pursued through nanostructuring and powder metallurgy. This study was aimed at the development of hard magnetic properties in bulk as-cast alloys and in melt-spun alloys for very low wheel speeds. Slower solidification rates and alloying with Zr promote the tetragonal ThMn 12 -type crystal structure, whereas higher solidification rates and alloying with B replace the ThMn 12 structure type with the TbCu 7 structure type. When introduced simultaneously, Zr and B dramatically reduce the alloy solidification rates required for both the refinement of the 1:12 crystallites and their replacement with the 1:7 phase. In bulk arc-melted alloys, this allowed for a microstructure of separated 1:12 crystallites 1–3 μm in size, although, because of the ferromagnetic nature of a minority phase, the coercivity of these fine-grained alloys reached only 0.73 kOe. A moderately accelerated solidification further refined the 1:12 crystallites and increased the coercivity; a Sm 0.7 Zr 0.4 (Fe,Co) 10.8 Ti 0.7 B 0.5 alloy exhibited a coercivity of 1.5 kOe and a maximum energy product of 3.4 MGOe when it was melt-spun into a 0.26-mm-thick ribbon. A more rapid solidification suppressed the 1:12 phase and after annealing at 800–850 °C, the alloys modified with Zr and B developed reasonably high coercivity and maximum energy product even when melt-spun at a wheel speed of 6 m/s. For the above-mentioned alloy, these values were 4.1 kOe and 7.8 MGOe, respectively. Further, a similarly processed very-Sm-lean Sm 0.5 Zr 0.6 (Fe,Co) 10.6 Ti 0.7 B 0.7 alloy exhibited a remanence of 8.8 kG and an energy product of 7.4 MGOe.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Electronic Structure and Spin Correlations in Novel Magnetic Structures

The research has advanced understanding of the interrelation between the crystal structure and magnetism in several materials which are or can be of interest for the development of improved, specialized or more cost-effective permanent magnets, as well as in selected materials for biomedical and catalytic applications. Fundamental aspects of ferromagnetism were investigated for Mn-Ge, Co-V and Co-Ge nanoclusters and for melt-spun Co-Sn alloys. New solution-chemistry synthesis methods were designed and tested for Fe-Pt, Fe3C and Fe3O4 nanoparticles. Off-stoichiometric Laves phases in the Fe-Si-Zr, Fe-Nb and Fe-Ta systems, as well as Fe5(Si,Ge)B2 compounds were assessed as new rare-earth-free permanent magnet materials; all except the Fe-Si-Zr Laves phases were found to be promising enough to merit a further exploration. A new method for manufacturing rare-earth-free magnets based on the MnBi compound was developed; by purposely avoiding oxidation-sensitive fine single-crystalline powders, the new method yields magnets with a 50% larger energy storage capacity. Studies of rare-earth-lean permanent-magnet materials (lean compared to the currently predominant Nd-Fe-B materials) were focused on the tetragonal compound of the ThMn12 structure type and included both discovery and characterization of new formulations and exploration of new fabrication/processing techniques. Among the most significant achievements were successful preparation of a vanadium-lean SmFe11V compound, the first observation of thermomechanically induced texture in nanocrystalline Sm(Fe,V)12 alloys, and a breakthrough reduction-diffusion synthesis of Sm1-xZrx(Fe0.8Co0.2)11.2Ti0.8 single-crystal particles with a coercivity as high as 12.6 kOe. Several experiments aimed at improvement of the Nd-Fe-B magnet have also been undertaken including a five-fold increase of the coercivity through a grain-boundary diffusion treatment of a Nd10Fe84B6 nanocrystalline alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Isotropic nanocrystalline Sm(Fe,Co) 11.3 Ti 0.7 magnets modified with B and Zr

Rare-earth-lean Sm(Fe,Co,Ti) 12 alloys with the ThMn 12 crystal structure and less than one Ti atom per formula unit have the potential of exceptionally powerful permanent magnets, but all prior attempts to develop high coercivity in bulk alloys, especially coercivity combined with crystallographic texture, have fallen short of the expectations. This study was aimed at improvement of the currently best Sm(Fe,Co,Ti) 12 magnets prepared through melt-spinning which are inherently isotropic. Modifications of the alloys with B and Zr, already demonstrated in earlier studies to be effective separately, have been implemented simultaneously. Here, a systematic study of Sm 1.1-x (Fe,Co) 11.3-y Ti 0.7 B y alloys melt-spun at a tangential speed of 50 m/s and annealed at 600–950 °C allowed for monitoring the continuous evolution of the two consecutive crystal structures, those of the TbCu 7 and ThMn 12 types. Zirconium was found to facilitate the formation of the 1:12 structure at the expense of the 1:7, whereas boron has the opposite effect, at certain concentrations completely suppressing the 1:12. When the two alloying elements are introduced simultaneously, they inhibit growth of the 1:12 crystallites at annealing temperatures higher than 800 °C, thus allowing for the development of a higher coercivity. Because of instrumental limitations, bulk magnets were prepared through a two-step process – compaction of the melt-spun ribbons at 650 °C and additional treatment at a higher temperature – and they were characterized by a reduced, 90–93%, density. Nevertheless, an isotropic Sm 0.9 Zr 0.2 (Fe,Co) 10.8 Ti 0.7 B 0.5 magnet exhibited fair values of the remanence (7.4 kG), maximum energy product (8.5 MGOe) and coercivity (5.4 kOe), as well as high Curie temperature of 525 °C and remarkably small temperature coefficient of the coercivity, -0.25%/°C.

36 MATERIALS SCIENCE↗
DOE OSTI2021

High-coercivity ThMn 12 -type monocrystalline Sm–Zr–Fe–Co–Ti particles by high-temperature reduction diffusion

The ThMn 12 -type (Sm,Zr)1(Fe,Co,Ti) 12 compounds have the potential of powerful permanent magnets. Magnetically hard and anisotropic powders of such compound have been prepared by subjecting elemental oxides and Co mixed with Ca and CaO dispersant to a succession of high-energy ball-milling, reduction diffusion at 990–1220 °C and repeated washing. The size of the resulting ThMn 12 -type crystallites, their coercivity and fraction of monocrystalline particles were all found to increase with the reduction-diffusion temperature. Particles synthesized at 1220 °C were highly monocrystalline with a mean size of 0.54 μm and, after a magnetic-field alignment, exhibited a coercivity of 1.26 T and a full-density-projected maximum energy product of at least 209 kJ/m 3 (26.3 MGOe). Here, the strong positive effect of the reduction-diffusion temperature on the coercivity has been attributed to separation of the crystallites and to decrease in the incidence of structural defects.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Structural and magnetic properties of iodide-mediated chemically synthesized L1 2 FePt 3 nanoparticles

In this work, we study the effect of elemental iodine as a halide intermediary in the synthesis of FePt 3 nanoparticles using a co-reduction of Fe(acac) 3 and (NH 4 ) 2 PtCl 2 with 1,2-hexadecanediol. Our study shows that elemental iodine facilitates the formation of FePt 3 nanoparticles with the L1 2 structure. When iodine is not used, the as-made nanoparticles have mostly the disordered fcc FePt 3 structure. The as-made nanoparticles are ferromagnetic and have a Curie temperature close to 380 K. Annealing of the as-made nanoparticles leads to an increased particle size and a transformation to the ordered L1 2 FePt 3 phase. Nanoparticles annealed at 700°C for 30 minutes show a mixture of two magnetic phases, a ferromagnetic phase with a lower ordering temperature of ~300 K and an antiferromagnetic phase with a Néel temperature around 135 K.

36 MATERIALS SCIENCE↗