Electrochemical synthesis and characterization of a NdCo5 permanent magnet

NdCo5 was produced in a simple one-stage process by electro-deoxidising an inexpensive single phase solid oxide solution of Nd2O3 and Co3O4. The reduction was performed in molten CaCl2 at 900 °C and the cell operated at 3.1 V at a cathodic current density of 170 mA cm−2 for 12 hours. The magnetic properties of the product, measured using a vibrating magnetometer, closely matched that of pure and homogenous NdCo5. The reaction mechanism at the cathode is elucidated from partially reduced samples using electron microscopy, X-ray diffraction analysis and conductivity measurements.