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1999hadjipanayis JMMM Nanophase Hard Magnets
1999hadjipanayis JMMM Nanophase Hard Magnets
Abstract
The dramatic developments that occurred in nanophase hard magnetic materials over the last two decades are
reviewed. Much of the research was done after the discovery of Nd Fe B-based magnets in an attempt to develop more
economical Fe-based magnets with better properties. This led to the discovery of 1 : 12-based magnets, 2 : 17 nitrides and
carbides, and more recently, to nanocomposite magnets consisting of a "ne mixture of exchange coupled soft and hard
phases. Currently, much emphasis is devoted to nanocomposite "lms consisting of nanoparticles of a high anisotropy
material embedded in a non-magnetic matrix because they have a great potential for applications in high density
recording media. 1999 Elsevier Science B.V. All rights reserved.
0304-8853/99/$ - see front matter 1999 Elsevier Science B.V. All rights reserved.
PII: S 0 3 0 4 - 8 8 5 3 ( 9 9 ) 0 0 4 3 0 - 8
374 G.C. Hadjipanayis / Journal of Magnetism and Magnetic Materials 200 (1999) 373}391
Table 1
Magnetic properties of nanocrystalline magnets
were subsequently achieved in nanocomposite found this way [9,10]. It was soon realized that
magnets consisting of a mixture of exchange- these materials have a high coercivity that is much
coupled hard and soft phases. Coehoorn et al. [35], larger than that corresponding to bulk magnets,
produced a high reduced remanence of 0.8 with including sintered magnets. For example, melt-
a coercivity of 4 kOe in melt-spun Nd Fe B spun Nd Fe B samples can easily attain coercivity
alloys consisting of Fe B and Nd Fe B phases. beyond 15 kOe (Table 1), while the coercivity of
Ribbon samples containing mixtures of corresponding sintered magnets is below 10 kOe.
Nd Fe(Co) B#a-Fe (Co) and Pr Fe(Co) B# The higher the anisotropy of the material the larger
a-Fe(Co) were also shown to develop high reduced the coercivity is expected to be. In Tb Fe B and
remanence and coercivity [36]. Since then other DyFe B with H "220 and 150 kOe, respectively,
systems have been found, including Sm}Co [37], coercivities in excess of 60 kOe have been reported
Sm (Fe,Co) N [38], and Sm (Fe,Co) C [39]. [43]. Large values of coercivity can also be ob-
6 6
Reasonable values of coercivity can be realized in tained in the R Fe C system, but their processing
such mixtures, even with 10 vol% of the hard is more subtle because of a phase transformation in
phase. the system from Nd Fe C to Nd Fe C [44].
6
Another class of nanocomposite materials is the The system must "rst be made into the primary
precipitation hardened 2 : 17 magnets with com- Nd Fe C soft phase with planar anisotropy be-
6
position Sm(Co,Fe,Cu,Zr) [40]. The complex fore being transformed into the anisotropic
X
microstructure of these bulk magnets consists of Nd Fe C.
a "ne mixture of cellular (with 2 : 17 cells sur- After the discovery of the R Fe B(C) com-
rounded by 1 : 5 walls) and lamellar patterns (Z- pounds with large coercivities in crystallized melt-
phase) [41]. The interplay between the size and spun ribbons, other compounds were made in the
chemical composition of these phases controls both nanocrystalline state and their magnetic properties
the magnitude and temperature dependence of co- are listed in Table 1. The Sm(Fe,M) tetragonal
ercivity. compounds were stabilized by small substitutions
The title chosen for this article is very broad and of M"Mo, Ti, V, and also had large values of
can include many di!erent examples of novel mag- coercivity [45]. Later, the strongly anisotropic
netic materials. The present article is focused on Sm Fe N and Sm Fe C were discovered by
6 6
bulk materials, primarily on cast samples, ribbons, the interstitial gas modi"cation (IGM) process [46]
powders, and covers single-phase nanocrystalline with N and or C, and were also produced in the
and two-phase nanocomposite magnets, including nanocrystalline state [47]. The nitrogenation/car-
the exchange and precipitation hardened 2 : 17 bonation process was also applied to other systems
magnets. The only section referring to thin "lms is and the resulting properties are shown in Table
on granular solids with high anisotropy for high 1 [48].
density recording media (CoPt(FePt)/C(Ag) and
SmCo (Nd Fe B)/W). Special emphasis is given 2.1. Microstructure
to the role of particle/grain size in the property
microstructure relationship. The single-phase materials have a chemical com-
position very close to the stoichiometric composi-
tion of the hard magnetic phase to minimize the
2. Nanocrystalline single-phase materials presence of secondary phases. The nanocrystalline
state is usually obtained by rapid solidi"cation
In the 1980s, nanocrystalline rare earth inter- techniques and by mechanical alloying. In the for-
metallic compounds were used as a quick tool in mer, the nanostructure is obtained either by crys-
the search of new anisotropic phases for permanent tallizing the precursor amorphous alloy, formed by
magnets by simply crystallizing the amorphous melt-spinning, splat-cooling, and double roller, or
precursor and checking the coercivity of crystalliza- in situ by varying the cooling rate of the process
tion products [42]. In fact, the 2 : 14 : 1 phase was used [49]. In the latter, annealing is always
376 G.C. Hadjipanayis / Journal of Magnetism and Magnetic Materials 200 (1999) 373}391
Table 2
Magnetic properties of nanocomposite magnets
"nal equilibrium crystalline phases takes place in nucleation "eld would be very low if there was no
2}3 steps. For R Fe B/Fe type magnets, it is exchange coupling between the hard and the soft
found that a-Fe is crystallized "rst and there is phases. It is the exchange coupling that signi"-
always a metastable intermediate phase formed be- cantly increases the nucleation "eld and thus
fore the "nal development of equilibrium R Fe B. preserves a reasonable high coercivity. This e!ect is
The metastable phase in the case of R"Nd or Pr is known as &exchange hardening'. Several authors
characterized to have a BCC Y Fe B type struc- have studied the magnetic hardening in nanocom-
ture and a Curie temperature of about 2003C [81]. posite magnets by using theoretical analysis [68,84]
For R Fe B/Fe with R"Tb or Dy and or micromagnetic modeling simulations [75}77].
Sm Fe C /Fe magnets, a metastable phase with Kneller and Hawig [68] using a one-dimensional
6
TbCu (disorder hexagonal) structure appears be- model were able to qualitatively explain the greater
fore the "nal equilibrium 2 : 14 : 1 or 2 : 17 phases reversibility in the recoil curves. According to this
are developed, respectively [81,82]. This indicates model the highest coercivity is achieved when the
that the annealing temperature must be high size of the soft phase is twice the domain wall width
enough to obtain the hard phase and the annealing of the hard phase. Skomsky and Coey [84] have
time should be as short as possible to minimize the used an analytical approach to predict the nuclea-
grain growth of the a-Fe. However, in most cases, tion "eld and energy product in nanocomposite
the grain size of the a-Fe is found still too large magnets. According to their calculations the nu-
even under the optimum annealing condition and cleation "eld reaches a plateau when the diameter
that additional substitutions like Nb, Zr, or Cr of the soft inclusion in the hard matrix reaches the
have to be used to get "ner a-Fe grains as explained Bloch wall width of the hard phase. Fischer et al.
before. [77] and Schre# et al. [85] have found by using
micromagnetic simulations that exchange interac-
3.1.4. Magnetic hardening tions between the phases suppress the nucleation of
The coercivity of hard magnets can be generally reversed domains and thus preserve a high coerciv-
written as [83] ity. They also predicted that M and H decrease
with increasing grain size and that the magnetic
H "(2K /k M )a !N M , (1)
! ) properties are degraded by a non-uniform micro-
where K and M are the anisotropy and the satu- structure, which agrees well with the experimental
ration magnetization of the material and a and results [36,62,78,79]. All of these studies have
)
N are microstructure-dependent parameters shown that the coercivity of nanocomposite mag-
which describe the e!ect of the microstructure on nets depends strongly on the anisotropy "eld of the
the crystal "eld and the local internal dipolar "eld. hard phases and on the grain size of the soft phase
The "rst term represents the modi"ed magnetoc- which should be of the order of the domain wall
rystalline "eld due to inhomogeneities (grain width of the hard phase.
boundaries, second phase, impurities, voids, dislo-
cations, etc.) in the real microstructure and the 3.2. Precipitation hardened 2 : 17 magnets
second term the demagnetization "eld due to the
irregular shape of the grains. These magnets consist of a "ne mixture of 1 : 5
The magnetization reversal process in nanocom- and 2 : 17 [86] phases. SmCo has a hexagonal
posite magnets is more complicated due to the structure with a"0.5 nm and c"0.4 nm. Many of
coexistence of the hard and the soft phase which are the other intermetallic compounds can be derived
exchange coupled. The overall anisotropy constant from the 1 : 5 by replacing a fraction of rare earth
is reduced by the soft phase, which may be taken atoms with a pair of transition metals (known as
into account by replacing a with a "a a where dumb bells) [87]. The Sm Co structure with
) ) )
a is related to exchange coupling. Generally a"0.840 nm and c"1.217 nm is obtained by the
speaking, the coercivity is controlled by the nuclea- replacement of one-third of the Sm atoms with
tion of the reversed domains in the soft phase. This a pair of Co atoms. Whether the rhombohedral or
G.C. Hadjipanayis / Journal of Magnetism and Magnetic Materials 200 (1999) 373}391 383
Table 3
Magnetic properties of commercial magnets
hexagonal modi"cation of 2 : 17 is obtained de- phases [92]. In 1977, Ojima et al. [93] made the
pends on whether this replacement occurs such that important discovery that additional small substitu-
the resulting stacking sequence is of the AB- tions of Co with Zr (or Hf [94], Ti) allow a greater
CABC2or ABAB2type, respectively. Fe content in the magnet without the formation of
Rare earth cobalt permanent magnets have large Fe}Co phases, leading to energy products (BH)
energy products, which originate from their high exceeding 30 MGOe in o!-stoichiometric
magnetocrystalline anisotropy [88] which is pre- Sm(Co,Fe,Cu,Zr) magnets with 6.8)Z)7.4 re-
8
dominately due to the rare earth sublattice, because ferred to as R T in Table 3.
of the non-uniform charge distribution in the 4f
shell. In the SmCo magnet, the anisotropy "eld 3.2.1. Magnetic properties
exceeds 300 kOe and the coercivities produced are The 2 : 17 precipitation hardened magnets have
greater than 30 kOe. However, its lower magnetiz- an initial magnetization curve which is distinctly
ation limits the energy product to only 25 MGOe di!erent from those of other magnets [40]. The
(Table 3). The anisotropy "elds are weaker in virgin curve of low H magnets is typical of &uni-
Sm Co , but its higher magnetization leads to form domain wall pinning' (inside the grains) with
higher energy products above 30 MGOe. the magnetization slowly increasing until a critical
The development of 2 : 17 permanent magnets "eld (which is close to H ) beyond which it drasti-
was the result of intense research in the late 1960s cally increases to saturation (Fig. 12). The virgin
and 1970s. It was "rst found that partial substitu- curve of higher H magnets shows a larger increase
tion of Co with Cu causes the formation of precipi- at low "elds but not as much as that observed in
tates [89], which were found to pin the domain SmCo and Nd Fe B magnets. This behavior in-
walls and lead to high H (precipitation hardening). dicates a non-uniform domain wall pinning with an
Other studies [90] showed that the magnetization additional contribution from localized pinning at
can be further increased by partial substitution of grain boundaries.
Co with Fe, which also stabilizes the c-axis anisot- Our latest studies [95,96] on the development of
ropy. (This substitution is possible in the 2 : 17 magnets with high operating temperatures showed
system but not in the 1 : 5 system because the that large coercivities can be obtained in
SmFe phase does not exist.) However, at higher Sm(Co,Fe,Cu,Zr) over a range of Z values from
8
concentrations, Fe (which substitutes at the dumb Z"5.5}9.1. The best high temperature properties
bell sites) tends to destabilize the 2 : 17 structure are obtained on the lower Z magnets as shown in
upon cooling through the Curie temperature be- Fig. 13. The temperature dependence of coercivity
cause of strong negative exchange interactions [91] is also found to be very sensitive on the amount of
(due to the small Fe}Fe spacing at the dumb bell Cu in the magnet and on the size of cellular micro-
sites), and this leads to the formation of soft Fe}Co structure.
384 G.C. Hadjipanayis / Journal of Magnetism and Magnetic Materials 200 (1999) 373}391
3.2.2. Microstructure * magnetic domains ercivity. The cells (&50 nm) have the 2 : 17
The hard magnetic properties of the precipita- rhombohedral structure, and they are surrounded
tion-hardened 2 : 17 magnets can be achieved only by thin (4}10 nm) coherent walls with the 1 : 5
[40] through a series of complex heat treatments. hexagonal structure. In the higher coercivity 2 : 17
The sintered samples are "rst solution heat-treated magnets [13], the cells are apparently much coarser
at &12003C and then quenched to room temper- (&100 nm) (Fig. 14), and thin lamellae (&3.0 nm)
ature. The high coercivities are developed after an are superimposed on the cellular microstructure
aging heat treatment in the temperature range of (Fig. 15). According to Rabenberg [101], the lamel-
800}8503C followed by a slow cooling to 4003C (or lae have the 1 : 3 rare earth structure and lie along
step aging to 4003C) and then quenching to room (0 0 0 1) planes. On the other hand, Fidler et al.
temperature. Transmission electron microscope [102] claimed a 2 : 17 hexagonal structure for the
studies [13,97}100] reveal a "ne cellular micro- lamellae. The cell boundaries are found to be rich
structure in the 2 : 17 magnets with lower co- in Cu while Zr concentrates in the thin lamellae
G.C. Hadjipanayis / Journal of Magnetism and Magnetic Materials 200 (1999) 373}391 385
of coercivity, from large negative b (b"dH /d¹) to with size below 10 nm [110}112]. This size is close
a much smaller negative b to a positive b [95]. This to the superparamagnetic limit of existing materials
behavior can be explained by the fact that Cu is which makes them unsuitable for this application.
concentrated on the SmCo Cu cell boundaries Therefore, materials with high magnetocrystalline
\6 6
thus in#uencing the magnetic properties of the 1 : 5 anisotropy are needed to avoid thermal #uctu-
phase, which then interacts strongly with the do- ations and demagnetizing "elds that tend to de-
main walls to lead to the observed high coercivity. stabilize the magnetization of the recorded bits
[106}108]. Current studies have been focused on
3.2.3. Magnetic hardening nanocrystalline rare earth compounds [5,26] and
A number of magnetic hardening models have CoPt and FePt [27,28] because of their high an-
been proposed to explain the coercivity of these isotropy which are expected to have coercivities
magnets. A rough estimate of the coercivity can be greater than 2 kOe. We have recently started a pro-
obtained by considering the gradient in domain gram to obtain nanocomposite X/> "lms consist-
wall energy that exists across the cell boundaries ing of magnetically hard nanoparticles of X"
using the expression [105] H "(1/2M ) *c /d CoPt (FePt), rare earth intermetallic compounds,
where d is the domain wall thickness and *c the in a non-magnetic matrix >"Ag, C, W.
di!erence in domain wall energy across the cell The granular structure is obtained by "rst de-
boundary. Fidler et al. [106] used a di!erent ap- positing X/> "lms in a multilayer form (consisting
proach taking into account the magnetoelastic of 100 repetitions) and subsequently annealing the
coupling energy between magnetostrictive stresses samples in the temperature range of 500}8003C to
of domain walls and lattice deformation strains and form the desired phase as nanophase particles. The
obtained good agreement with the observed co- "lms were prepared by magnetron sputtering de-
ercivities. Paul [107] has treated the case of a 1803 position from two 2 targets of X and >. The base
domain wall interacting with planar defect and pressure of the chamber was 3;10\ Torr and
explained the observed coercivity in these magnets high purity Ar was used for deposition at ambient
as a function of defect size and the intrinsic proper- temperature with a pressure of 5 mTorr. In this
ties (A, K, M ) of the matrix and defect. section we present some preliminary results on
Monte Carlo simulations [109] were recently these materials.
performed on a simpli"ed model for the 2 : 17 mag-
nets to understand how the domain walls are de- 3.3.1. CoPt}FePt nanoparticles in Ag(C) matrices
pinned by a "eld at high temperatures. For large Co}Pt and Fe}Pt alloys with composition close
"elds, the domain walls are depinned from the cell to equiatomic have been studied extensively in the
boundaries. The depinning process begins with past, as possible candidates for permanent magnets
a kink occurring in the wall at the corner where the [113,114], because of the large value of magnetoc-
horizontal domain walls intersect the grain bound- rystalline anisotropy of the ordered face centered
aries. Physically, this idea is very reasonable. If one tetragonal (FCT) phase, resulting in coercivities
wants to move a carpet across a room, it is easier to greater than 5 kOe. These alloys usually undergo
create a rumple (corresponding to the kink) in the a phase transformation at below 8003C from a dis-
carpet and move the rumple across the room. This ordered face centered cubic (FCC) phase at high
suggests that if the grains are longer, or if the temperatures to the ordered FCT phase at lower
corners are eliminated, the coercivity will be in- temperatures. Recently FePt and CoPt "lms have
creased. received considerable attention for magnetic re-
cording and magneto-optical recording applica-
3.3. Granular xlms with high anisotropy materials tions [27]. Granular CoPt/C "lms consisting of
Co-rich hexagonal Co}Pt particles in a C matrix
The drive for higher magnetic recording density have been reported by Delaunay et al. [115].
with a low system noise impose the need for a me- However, the "lms had a low coercivity because of
dium consisting of magnetically isolated grains the lower anisotropy of the hexagonal Co-rich
G.C. Hadjipanayis / Journal of Magnetism and Magnetic Materials 200 (1999) 373}391 387
0.96K <
H" 1! , (2)
M <
Fig. 22. Typical microstructure in SmCo /W "lms.
where < is the critical volume for superparamag-
netism, estimated by K< "25k¹. The bulk value
from 5 to 35 nm for both. The total "lm thickness
K gives a volume as small as < "21 nm which
was kept around 1 lm. All "lms were covered by
corresponds to a particle size of 2.5 nm. The TEM
studies show a particle size in the range 7}26 nm a 100 nm layer of = for protection.
which would account only for a reduction of co- Magnetic measurements on the as-made "lms
ercivity around 20%. Another possibility for the showed an amorphous-type behavior. The coerciv-
explanation of this discrepancy is the consideration ity, at room temperature, did not exceed 50 Oe. The
of the interaction e!ects, which are expected to lead "lms were annealed at various temperatures
to remanence enhancement accompanied by reduc- ranging from 500 to 9003C at di!erent annealing
tion of the coercivity [117]. However, for interac- times (5}50 min) in a vacuum with base pressure
tions related to m "0.78 the expected reduction of better than 1;10\ Torr. This process resulted in the
breaking of the multilayer structure and led to nano-
coercivity is around 10% [118]. Therefore, interac-
tion e!ects cannot explain the large di!erence that particles of magnetically hard SmCo (Nd Fe B)
is observed even in samples with isolated grains. phases embedded in a = matrix (Fig. 22).
The large discrepancy may be related to the fact Preliminary results show that at low annealing
that for the relatively short annealing times which temperatures (up to 6003C) the hysteresis loop was
are used to optimize the microstructure, the order- quite square with coercivities between 1 and 6 kOe
ing of the FCT phase is not complete. The splitting (Fig. 23). At higher annealing temperatures
of the (0 0 2)}(2 0 0) re#ections in the XRD patterns ('7003C) a shoulder appears on the demagnetizing
corresponds to a ratio c/a"0.99 compared to the curve which may be due to the development of
bulk value of c/a"0.97 and consequently anisot- a second soft phase. For these "lms typical values of
ropy is expected to be lower than that of the bulk H were between 10 and 20 kOe for these "lms.
value. Furthermore a reduced K would give a lower
< and lead to an enhanced size dependence ac-
cording to Eq. (2). 4. Projections
Acknowledgements
Fig. 23. Typical hysteresis loop of SmCo /W thin "lm after
annealing.
Work supported by MURI, DOE and NSF.
I would like to thank Dr. Zhongmin Chen and Joe
C. Christodoulides for their help in this article and
isolated and compacted nanoparticles/nanograins Dr. Niarchos's group at &Demokritos' National Re-
of materials with high anisotropy, including the search Lab in Athens, Greece for their collabora-
rare earth intermetallic compounds. In such tion on CoPt/Ag(C) "lms.
nanoparticles (nanograins), the surface atoms con-
stitute most of the particles and the broken sym-
metry at the surface and di!erence in bonding and References
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