Improved oxidation resistance of SmCo magnetic alloy powders by silanization

The thermal stability of Sm2Co17 powders coated with four different silanes was studied between 25 degrees C and 500 degrees C and isothermally at 400 degrees C. Thermogravimetry data indicated that the silane-based coatings provided improved oxidation resistance. The microstructural analysis of uncoated powders oxidized for 10 h at 400 degrees C revealed the formation of a featureless ca. 10 mu m thick shell, surrounding the unreacted core. The development of this shell was attributed to the inward diffusion of oxygen, decomposition of intermetallic phases and redistribution of alloying elements. The EDS elemental maps revealed that the shell was rich in O, Fe and Co, and depleted in Sm, Zr and Cu. In the presence of the silane-based coatings the thickness of the shell was reduced by more than 80% (to less than 2 mu m) and the redistribution of alloying elements was insignificant. Based on the thermogravimetric analysis at or above ca. 400 degrees C and the nnicrostructural analysis it was possible to assess the relative effectivity of the different silanes in preventing the oxidation of the SmCo powder. Methyltrimethoxysilane (MTMS), which also formed the thinnest coating, was the best silane. (3-Glycidyloxypropyl)trimethoxysilane, forming a thicker coating, was less effective than MTMS, but superior to the two amine-functionalized silanes ((3-aminopropyl)triethoxysilane and (3-aminopropyl)trimethoxysilane). (C) 2012 Elsevier B.V. All rights reserved.