Materials Science Forum, Vol.465-466, 93-100, 2004
Shock compaction of bulk nanocomposite magnetic materials
Dynamic shock compaction offers the potential of fabricating bulk nanocrystalline functional materials via consolidation of amorphous or nanocrystalline alloy powders, while retaining the metastable structure and/or nanograin size of starting powders. In this work, gas-gun impact, double-tube explosion and underwater explosion techniques were utilized to consolidate exchange-coupled R2Fe14B/alpha-Fe (R=Nd, Pr) hard/soft phase nanocomposite powders. Design of the consolidation fixtures, densification conditions, and starting powder properties allowed control of the final density and the nanoscale structure of the hard/soft magnetic phases in the recovered shock-compacted samples. Highly dense compacts (similar to99% of full density) were obtained under optimized shock consolidation conditions. Transmission electron microscopy observations revealed complete retention of the nanostructure, which was within 15-25 nm in the final shock-compacted composite magnets. Retention of the nano-scale structure in the shock consolidated compacts ensured exchange coupling between the hard and soft phases, resulting in optimal magnetic properties. In this paper, the unique attributes of the shock-densification process in forming and retaining the nanocrystalline structure, and therefore leading to improved magnetic properties will be described.