Liquid metal extraction (LME), a pyrometallurgical recycling method, is popular owing to its negligible environmental impact. LME mainly targets rare-earth permanent magnets having several rare-earth elements. Mg is used as a solvent metal for LME because of its selective and eminent reactivity with rare-earth elements in magnets. Several studies concerning the formation of Dy-Fe intermetallic compounds and their effects on LME using Mg exist. However, methods for reducing these compounds are unavailable. Fe reacts more strongly with B than with Dy; B addition can be a reducing method for Dy-Fe intermetallic compounds owing to the formation of Fe2B, which takes Fe from Dy-Fe intermetallic compounds. The FeB alloy is an adequate additive for the decomposition of Fe2B. To accomplish the former process, Mg must convey B to a permanent magnet during the decomposition of the FeB alloy. Here, the effect of Mg on the transfer of B from FeB to permanent magnet is observed through microstructural and phase analyses. Through microstructural and phase analysis, it is confirmed that FeB is converted to Fe2B upon B transfer, owing to Mg. Finally, the transfer effect of Mg is confirmed, and the possibility of reducing Dy-Fe intermetallic compounds during LME is suggested.

Rare earth magnets with excellent magnetic properties are indispensable in the electric device, wind turbine, and e-mobility industries. The demand for the development of eco-friendly recycling techniques has increased to realize sustainable green technology, and the supply of rare earth resources, which are critical for the production of permanent magnets, are limited. Liquid metal extraction (LME), which is a type of pyrometallurgical recycling, is known to selectively extract the metal forms of rare earth elements. Although several studies have been carried out on the formation of intermetallic compounds and oxides, the effect of oxide formation on the extraction efficiency in the LME process remains unknown. In this study, microstructural and phase analyses are conducted to confirm the oxidation behavior of magnets pulverized by a jaw crusher. The LME process is performed with pulverized scrap, and extraction percentages are calculated to confirm the effect of the oxide phases on the extraction of Dy during the reaction. During the LME p rocess, Nd i s completely e xtracted a fter 6 h, w hile D y remains as D y2Fe17 and Dy-oxide. Because the decomposition rate of Dy2Fe17 is faster than the reduction rate of Dy-oxide, the importance of controlling Dy-oxide on Dy extraction is confirmed.

본 연구는 R-B & HDDR process를 적용해서 Nd-Fe-B계 회토류 이방성 본드자석의 제조를 위한 기초 데이터를 확보할 목적으로. 환원확산법을 사용해서 Nd-Fe-B계 자석합금분말을 제조하는 데 필요한 금속 Ca에 의한 Nd2O3의 환원반응과 Fe-B합금분말중에서의 Nd확산반응을 조사하였다. 그 결과 Nd2O3의 환원시 필요한 최적의 Ca첨가량은 1000˚C에서 1h동안 R-D 반응후 Nd 및 B원소의 수율관계로부터 이론당량의 1.3배정도가 적량인 것으로 나타났다. 또한 Fe-B합금분말중에 Nd의 확산과 관련된 XRD의 분석결과에 따라 완전한 균질화를 위해서는 1100˚C에서 45min정도의 R-D반응이 필요하였으며, R-D반응에 대한 Nd의 수율도 그 조건에서 최대로 얻어졌다. 그리고 수세후의 최종 분말시료중에 잔류하는 Ca 및 O2량을 ICP발광분석 및 산소분석기에 의해 분석한 결과, 각각의 함유량은 0.17 및 0.42wt%정도가 검출되었다

환원.확산법에 의해 Sm2Fe17Nx 계 희토류 영구자석을 제조하기 위한 기초연구로서, 우선 Sm2Fe17 금속간화합물의 제조를 위하여, 금속 Ca에 의한 Sm2O3의 환원반응과 Fe분말중에 Sm의 확산반응을 검토하였다. 그 결과 전자는 1000˚C이상의 고온의 경우에 매우 빠르게 완료되지만, 후자의 Fe분말의 중심까지 Sm의 확산반응의 완료(완전한 균질화조건)는 1100˚C에서 3h 정도의 R-D 반응이 필요하며, 이 확산반응이 전체반응에 있어서 율속단계임을 알았다. Sm-Fe 계의 금속간화합물들의 성장은 1000˚C이하에서는 SmFe2, SmFe3,Sm2Fe17금속간화합물의 3개의 상이 관찰되었으나, 1100˚C에서는 Sm2Fe17 금속간화합물의 상만이 관찰되었다. 본 연구에서 얻어진 최종시료의 산소 및 Ca량은 각각 0.72wt% 및 0.11wt%이었다.