Cerium Substitution Boosts NdFeB Magnet Performance Using Two-Powder Manufacturing

Highlights

• At 7 wt.% cerium, the 2-powder method achieved 1.31 T remanence and 1,054 kA/m coercivity, outperforming conventionally processed magnets with the same Ce content.
• The technique redistributes rare earths during sintering, concentrating Nd/Pr near grain surfaces without requiring a separate post-sintering diffusion treatment.
• Replacing 10–15% of rare-earth content with cerium could reduce critical-REE consumption comparably and lower raw-material costs roughly 10%.
• Maximum energy product remained about 12% below the Ce-free benchmark, making this more a NdPr-thrifting technology than a full replacement.
• The study is a non-peer-reviewed preprint based on lab-scale specimens; industrial yield, throughput, and mass-production reproducibility remain unvalidated.