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Rare-earth-free magnets are highly demanded by clean and renewable energy industries because of the supply constraints and environmental issues. A promising permanent magnet should possess high remanent magnetic flux density (Br), large coercivity (Hc) and hence large maximum magnetic energy product ((BH)max). Fe16N2 has been emerging as one of promising candidates because of the redundancy of Fe and N on the earth, its large magnetocrystalline anisotropy (Ku > 1.0 × 107 erg/cc), and large saturation magnetization (4πMs > 2.4 T). However, there is no report on the formation of Fe16N2 magnet with high Br and large Hc in bulk format before. In this paper, we successfully synthesize free-standing Fe16N2 foils with a coercivity of up to 1910 Oe and a magnetic energy product of up to 20 MGOe at room temperature. Nitrogen ion implantation is used as an alternative nitriding approach with the benefit of tunable implantation energy and fluence. An integrated synthesis technique is developed, including a direct foil-substrate bonding step, an ion implantation step and a two-step post-annealing process. With the tunable capability of the ion implantation fluence and energy, a microstructure with grain size 25-30 nm is constructed on the FeN foil sample with the implantation fluence of 5 × 1017/cm2.
Bibliographical noteFunding Information:
This work was supported in part by ARPA-E (Advanced Research Projects Agency-Energy) BCT Fe16N2 Magnet project under contract No. 0472-1595. Parts of this work were carried out in using the Characterization Facility, which receives partial support from NSF through the NSF Minnesota MRSEC program under Award Number DMR-0819885. Ion implantation was supported by Center for Integrated Nanotechnologies (CINT), a DOE nanoscience user facility jointly operated by Los Alamos and Sandia National Laboratories.