Modeling of Unoriented Dendritic Grain Structures in Hard–Soft Magnetic Composites

This paper investigates the magnetization reversal processes in spring-exchange magnetic composites featuring irregular, dendritic structures. A disorder-based cluster Monte Carlo method combined with a Diffusion-Limited Aggregation (DLA) algorithm was used to model a fractal-like soft magnetic phase (Fe) embedded in a high-coercivity hard matrix (Fe-Nb-B-Dy). A multiparameter analysis was performed by varying the soft phase volume fraction (10–30%), intergrain exchange coupling via contact bridges (25–100%), system scale factors (1–20), surface-to-volume anisotropy ratios (KS/KV = 1–20), and the degree of random anisotropy contribution (RAC = 0–100%). The simulations reveal that highly branched fractal structures enhance the interfacial contact area, which accelerates the nucleation of domain reversal driven by the soft phase, paradoxically lowering the overall coercivity compared to compact morphologies. Furthermore, a lack of easy magnetization axis coherent alignment triggers a cascading reversal mechanism through local “weak links”, severely degrading the coercive field from approximately 4.2 T to below 0.4 T in extreme cases (at 30% Fe, 25% coupling and high KS/KV ratio). These findings suggest potentially the most important factors and their impact that should be taken into account in the design and optimization of next-generation powder-sintered permanent magnets.