This work investigates the fabrication and performance of axially compressed isotropic epoxy-bonded NdFeB-type magnets produced from melt-spun powders with partial substitution of (Nd,Pr) by (La,Ce). Four alloy compositions were synthesized and processed into bonded magnets using two powder-to-binder weight ratios (95:5 and 96.5:3.5). Structural analysis confirms that all substituted alloys retain the tetragonal Nd2Fe14B phase (up to ~95 wt%) even at high substitution levels, while the lattice parameters decrease slightly with increasing (La,Ce) content. Microscopy analysis confirms a homogeneous distribution of the binder phase around the powder particles, demonstrating uniform binder–powder integration. Thermal analysis reveals composition-dependent Curie temperatures and enhanced crystallization onset in highly substituted powders. Magnetic measurements on both powders and bonded magnets show that increasing substitution leads to a gradual reduction in remanence, coercivity, and energy product, though all samples maintain strong hard-magnetic behavior. Increasing the powder fraction to 96.5 wt.% significantly improves all magnetic parameters due to higher magnetic-phase density and enhanced interparticle coupling, yielding bonded magnets with densities up to ~80% of the theoretical value. The resulting magnets achieve competitive performance, uniform field distribution and isotropic magnetization with (BH)max values about 65 kJ/m3, a coercivity around 660 kA/m, and superior thermal stability compared with commercial bonded NdFeB magnets. Overall, partial substitution with light rare-earth elements (La,Ce) provides a cost-effective route to high-density bonded NdFeB magnets that combine strong magnetic performance, enhanced thermal stability, and suitability for lightweight, complex-shaped industrial applications. Surprisingly, the coefficients of the temperature variation of coercivity and (BH)max are much better compared to the commercial NdFeB bonded magnets.
Dimeli et al. (Mon,) studied this question.