Electrochemical Behaviour of Nd–Fe–B and Sm–Fe–N Polymer-Bonded Magnets and Their Metal Components in Various Electrolytes

Polymer-bonded Nd–Fe–B and Sm–Fe–N magnets have excellent magnetic properties, but their corrosion resistance is inferior. Polymer-bonded magnets, the binary alloys Nd–Fe and Sm–Fe, and the metals Fe, Nd, and Sm were investigated in electrolytes with a pH range of 1.8 to 12.8. Potentiodynamic polarisation measurements showed that these materials corrode in acidic (H2SO4) and near-neutral (Na2SO4 and NaCl) electrolytes. Iron passivates at pH > 9, but Nd and Sm passivate only in strongly alkaline electrolytes (pH > 12). The alloys and magnets combine the characteristics of the individual metals. Scanning electron microscopy with energy-dispersive X-ray spectroscopy characterised the surface layers before and after electrochemical measurements. The speciation and the depth distribution of elements in the surface layers were analysed using X-ray photoelectron spectroscopy. In the H2SO4, a non-protective layer was formed. In NaCl, the corrosion products were more abundant, consisting of a mixture of oxides, hydroxides, and chlorides, while in NaOH, an oxide/hydroxide layer was formed. The corrosion product layers formed in the H2SO4 and NaCl electrolytes were significantly thicker for the Sm–Fe–N magnet than for the Nd–Fe–B magnet. Understanding the differences and similarities in the electrochemical behaviour of magnets in various electrolytes is essential to overcoming corrosion-related problems.