In-situ thermo-mechano-chemical transformation and consolidation of Sm-Co powders via a single-step route for bulk magnet fabrication

Aniruddha Malakar, Andrew Martin, Farhan Ishrak, Caleb Schenck, Anqi Yu, Mayur Pole, Jens Darsell, Tianhao Wang, Joseph Helsing, John Thornton, Michael Lastovich, Libor Kovarik, Glenn Grant, Joseph B. Tracy, Martin Thuo, Mert Efe () and Bharat Gwalani ()
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Aniruddha Malakar: North Carolina State University
Andrew Martin: North Carolina State University
Farhan Ishrak: North Carolina State University
Caleb Schenck: North Carolina State University
Anqi Yu: Pacific Northwest National Laboratory
Mayur Pole: Pacific Northwest National Laboratory
Jens Darsell: Pacific Northwest National Laboratory
Tianhao Wang: Pacific Northwest National Laboratory
Joseph Helsing: Stevens Institute of Technology
John Thornton: AFM Unit
Michael Lastovich: North Carolina State University
Libor Kovarik: Pacific Northwest National Laboratory
Glenn Grant: Pacific Northwest National Laboratory
Joseph B. Tracy: North Carolina State University
Martin Thuo: North Carolina State University
Mert Efe: Pacific Northwest National Laboratory
Bharat Gwalani: North Carolina State University

Nature Communications, 2025, vol. 16, issue 1, 1-12

Abstract: Abstract The demand for high-performance permanent magnets continues to grow across a wide range of advanced technologies. However, conventional powder metallurgy routes for rare-earth magnets such as Sm–Co are limited by the intrinsic brittleness of the powders, reducing manufacturability and yield. Here, we report a single-step, solid-state processing method—friction consolidation (FC)—that enables simultaneous deformation, heating, and chemical transformation of brittle Sm–Co powders. Using commercial SmCo₅ powders containing Sm₂Co₇, FC induces a thermo-mechano-chemical pathway in which Sm₂Co₇ undergoes oxidation to form nanoscale SmCo(5–x) (where x

Date: 2025
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DOI: 10.1038/s41467-025-62804-9

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