Eddy-current-resistant SmCo5/CaF2 magnets produced via high-energy milling in polar and non-polar liquids

Processes of high-energy ball milling of SmCo₅ alloys were compared for three single-liquid environments without using additional surfactants. Both coarsely grained as-cast and nanocrystalline pre-milled SmCo₅ precursors showed tendency toward formation of thin flakes if milled in polar liquids (acetone and ethanol) in a marked contrast to milling in non-polar heptane. CaF₂ dielectric powder added prior to milling in the polar liquids tends to become attached on the flake surfaces. Milling in heptane in the presence of CaF₂ produces flake-like SmCo₅ particles which with increasing the milling time are found to incorporate an increasing amount of CaF₂. The SmCo₅—5 wt% CaF₂ mixtures milled for the optimum time in both the polar and non-polar liquids were successfully hot-pressed into laminated composite magnets having intrinsic coercivity of 25–30 kOe, maximum energy product of approximately 6.5 MG Oe and electrical resistivity of 500–600 μΩ cm, which is more than 7 times the resistivity of conventional Sm–Co magnets.