Combinatorial search of rare-earth free permanent magnets

Permanent magnets play important roles in modern technologies such as in generators, motors, speakers, and relays. Today's high performance permanent magnets contain at least one rare earth element such as Nd, Sm, Pr and Dy. However, rare earth elements are increasingly rare and expensive, and alternative permanent magnet materials which do not contain them are needed by the industry. We are using the thin film composition spread technique to explore novel compositions of permanent magnets without rare-earth. Ternary co-sputtering is used to generate composition spreads. We have thus far looked at Mo doped Fe-Co as one of the initial systems to search for possible compounds with enhanced coercive fields. The films were deposited on Si (100) substrates and annealed at different temperatures. The structural properties of films are mapped by synchrotron diffraction. We find that there is a structural transition from a crystalline to an amorphous state at about 20{\%} atomic Mo. With increasing annealing temperature, the Mo onset concentration of the structural transition increases from 25{\%} for 600$^{\circ}$C to 35{\%} for 700$^{\circ}$C. We find that some of compounds display enhanced coercive field. With increasing Mo concentration, the magnetization of Fe-Co-Mo begins to switch from in-plane to out-of-plane direction. This work is funded by the BREM (Beyond Rare-earth Magnet) project (DOE EERE).