Improvement of Mechanical Properties and Electrical Resistivity in Giant Magnetostrictive Tb-Dy-Fe Alloy via Co-Addition of Al and Si Elements

Giant magnetostrictive Tb-Dy-Fe alloys are extensively applied in transducers, actuators, and smart sensors owing to their exceptional magnetostrictive response. Nevertheless, in addition to the fracture failure caused by the inherent brittleness of the Laves intermetallic compound, Tb-Dy-Fe alloys also suffer from severe eddy current losses due to low electrical resistivity, both of which limit the practical application of Tb-Dy-Fe alloys. To further enhance the overall performance of Tb-Dy-Fe alloys and expand their application scope, it has become essential to develop materials that exhibit high magnetostrictive properties, high electrical resistivity and excellent mechanical properties simultaneously. In this work, the effects of Al and Si co-addition on the microstructure and multifunctional properties of directionally solidified Tb0.27Dy0.73(Fe0.9Al0.075Si0.025)1.95 (hereafter TDF-AlSi) alloy were systematically investigated. Microstructural characterization revealed that Al partially substitutes Fe atoms in the matrix phase while promoting Al(Tb,Dy)Fe2 nanocluster, whereas Si preferentially segregated to grain boundary regions forming Tb2Si3 and TbSi1.75 phases. The bending strength of TDF-AlSi alloy was improved from 43 MPa to 65 MPa, an increase of 51.2%, which was attributed to solid solution strengthening by Al and grain boundary reinforcement by Si-rich precipitates. Meanwhile TDF-AlSi alloy exhibits a 2.4 times increase in electrical resistivity (1.619 μΩ·m), resulting in a 49% reduction of total loss at 1000 Hz. The enhancement of electrical resistivity mainly originated from the lattice distortion induced electron scattering by Al substitution and electron impedance at grain boundaries via silicide precipitation. Accompanied by enhancement of mechanical property and electrical resistivity, TDF-AlSi alloy maintained a high magnetostriction strain of 1212 ppm (200 kA/m, 10 MPa pre-compressive stress). The findings of the present study offer valuable theoretical and experimental insights with regard to the optimization of the performance of magnetostrictive Tb-Dy-Fe alloys.