Dysprosium transport in Nd-Fe-B pellets

The addition of heavy rare earth (RE) elements to Nd2Fe14B based magnets to form (Nd,Dy)2Fe14B is known to increase the coercivity and high temperature performance required for hybrid vehicle electric motors and other extreme temperature applications. Attempts to conserve heavy rare earth elements for high temperature (RE)2Fe14B based magnets have led to the development of a grain boundary diffusion process for bulk magnets. This process relies on transport of a heavy rare earth, such as Dy, into a bulk Nd2Fe14B magnet along pores, a low volume fraction of eutectic liquid along grain boundary grain triple junctions and grain boundaries. This enriches the grain surfaces in Dy through the thickness of the bulk magnet, leading to larger increases coercivity with a smaller Dy concentration than can be achieved with homogeneous alloys. Attempts to carry out the same process during sintering require significant control of Dy transport efficiency. The macroscopic transport of Dy in Nd2.7Fe14B1.4 based powder packs is studied using a 'layered' pellet, where Nd2.7Fe14B1.4powder is an interlayer and Dy source as a center layer. The sintering of this layered pellet provided evidence for very large effective diffusion lengths aided by Dy rich liquid flow through connected porosity. Approaches to controlling Dy transportation include decreasing the liquid phase transport capability of the powder pack by increasing the melting point of the Dy source and the decreasing amount of RE rich liquid in the powder packs. The solid-liquid reaction is studied in which melt spun Nd2.7Fe14B1.4 ribbons are PVD coated with Dy-Fe eutectic composition and then thermally treated. The resulting microstructure from the reaction between Dy-Fe eutectic coating and Nd2.7Fe14B1.4 ribbon is interpreted as support for a proposed dissolution/reprecipitation process between solid and liquid phases. The estimate the diffusion coefficient and the effective diffusion length of Dy sources in Nd2.7Fe14B1.4 layered pellets and melt spun ribbons were obtained from the calculation of Fick's second law combined with EDS results from the experiment. The results indicate that the effective diffusion coefficient of Dy in the layered pellets is higher than the diffusion in ribbons due to its higher porosity than ribbons.

DEVELOPMENT OF AN IONIC LIQUID FERROFLUID ELECTROSPRAY SOURCE AND MODE SHAPE STUDIES OF A FERROFLUID IN A NON-UNIFORM MAGNETIC FIELD

An electrospray source has been developed using a novel new fluid that is both magnetic and conductive. Unlike conventional electrospray sources that required microfabricated structures to support the fluid to be electrosprayed, this new electrospray fluid utilizes the Rosensweig instability to create the structures in the magnetic fluid when an external magnetic field was applied. Application of an external electric field caused these magnetic fluid structures to spray. These fluid based structures were found to spray at a lower onset voltage than was predicted for electrospray sources with solid structures of similar geometry. These fluid based structures were also found to be resilient to damage, unlike the solid structures found in traditional electrospray sources. Further, experimental studies of magnetic fluids in non-uniform magnetic fields were conducted. The modes of Rosensweig instabilities have been studied in-depth when created by uniform magnetic fields, but little to no studies have been performed on Rosensweig instabilities formed due to non-uniform magnetic fields. The measured spacing of the cone-like structures of ferrofluid, in a non-uniform magnetic field, were found to agree with a proposed theoretical model.

Influence of Mechanical and Thermal Boundary Conditions on Stabilizing/Destabilizing Mechanisms in Evaporating Liquid Films

Liquid films, evaporating or non-evaporating, are ubiquitous in nature and technology. The dynamics of evaporating liquid films is a study applicable in several industries such as water recovery, heat exchangers, crystal growth, drug design etc. The theory describing the dynamics of liquid films crosses several fields such as engineering, mathematics, material science, biophysics and volcanology to name a few. Interfacial instabilities typically manifest by the undulation of an interface from a presumed flat state or by the onset of a secondary flow state from a primary quiescent state or both. To study the instabilities affecting liquid films, an evaporating/non-evaporating Newtonian liquid film is subject to a perturbation. Numerical analysis is conducted on configurations of such liquid films being heated on solid surfaces in order to examine the various stabilizing and destabilizing mechanisms that can cause the formation of different convective structures. These convective structures have implications towards heat transfer that occurs via this process. Certain aspects of this research topic have not received attention, as will be obvious from the literature review. Static, horizontal liquid films on solid surfaces are examined for their resistance to long wave type instabilities via linear stability analysis, method of normal modes and finite difference methods. The spatiotemporal evolution equation, available in literature, describing the time evolution of a liquid film heated on a solid surface, is utilized to analyze various stabilizing/destabilizing mechanisms affecting evaporating and non-evaporating liquid films. The impact of these mechanisms on the film stability and structure for both buoyant and non-buoyant films will be examined by the variation of mechanical and thermal boundary conditions. Films evaporating in zero gravity are studied using the evolution equation. It is found that films that are stable to long wave type instabilities in terrestrial gravity are prone to destabilization via long wave instabilities in zero gravity.