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This paper aims to investigate the corrosion kinetics and corrosion behavior of NdFeB magnets with the addition of heavy rare earth dysprosium (Dy) for its inhibitory activity on poor corrosion resistance of NdFeB magnets.

To study the effect of dysprosium addition on corrosion behavior of NdFeB magnets and investigate its mechanism, potentiodynamic polarization, scanning electron microscopy (SEM), electrochemical impedance, energy dispersion spectrum (EDS) and scanning Kelvin probe force microscopy (SKPFM) were applied in the research. Besides, microstructures were observed by SEM equipped with EDS. Atomic force microscopy was introduced to analyze the morphology, potential image as well as the contact potential difference. The SKPFM mapping scan was applied to obtain the contact potential around Nd-rich phase at 0.1 Hz. The magnets were detected via X-ray diffraction.

Substitution of Nd with Dy led to improvement of corrosion resistance and reduced the potential difference between matrix and Nd-rich phase. Corrosion resistance is Nd-rich phase < the void < metal matrix; maximum potential difference between matrix and Nd-rich phase of Dy = 0, Dy = 3 and Dy = 6 Wt.% is 411.3, 279.4 and 255.8 mV, respectively. The corrosion rate of NdFeB magnet with 6 Wt.% Dy is about 67% of that without Dy at steady corrosion stage. The addition of Dy markedly enhanced the corrosion resistance of NdFeB magnets.

This research innovatively investigates the effect of adding heavy rare earth Dy to NdFeB permanent magnets on magnetic properties, as well as their effects on microstructure, phase structure and most importantly on corrosion resistance. Most scholars are studying the effect of element addition on magnetic properties but not on corrosion resistance. This paper creatively fills this research gap. NdFeB magnets are applied in smart cars, robotics, AI intelligence, etc. The in-depth research on corrosion resistance by adding heavy rare earths has made significant and outstanding contributions to promoting the rapid development of the rare earth industry.