Tailoring Microstructure Orientation and Magnetic Properties in AlNiCo Permanent Magnets by Controlled Withdrawal Rate in High-Rate Solidification

Enhancing grain orientation along the crystal axis in AlNiCo alloys is crucial for developing high-performance permanent magnets. Traditional directional solidification, known as the “cold plate-hot mold” method, is constrained by a low thermal gradient, leading to inadequate microstructural uniformity and crystallographic alignment, which impedes the optimization of magnetic properties. In this study, we employed a high-speed solidification process with an enhanced cooling gradient to fabricate AlNiCo magnets at various withdrawal rates. The variation in drawing rate influenced grain orientation within the alloy, thereby altering the degree of alignment of the ferromagnetic α1 phase following subsequent heat treatment, which ultimately affected the magnetic properties. The optimal magnetic performance was attained at a withdrawal rate of 50 μm/s, where the sample exhibited the most favorable oriented microstructure, with a remanence (Br) of 10.62 kGs, intrinsic coercivity (Hcj) of 1.794 kOe, and a maximum energy product (BH)max of 10.93 MGOe. Moreover, magnets at different positions exhibit excellent consistency in magnetic properties, enhancing the material utilization efficiency. This research provides valuable process parameters and a foundational basis for developing high-performance AlNiCo alloys.