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We present a simple, scalable synthesis route for producing exchange coupledsoft/hard magnetic composite powder that outperforms pure soft and hard phaseconstituents. Importantly, the composites is iron oxide based (SrFe12O19 andFe3O4) and contain no rare earth or precious metal. The two step synthesisprocess consists of first precipitating, an Iron oxide/hydroxide precursordirectly on top of SrFe12O19 nano-flakes, ensuring a very fine degree of mixingbetween the hard and the soft magnetic phases. We then use a second step thatserves to reduce the precursor to create the proper soft magnetic phase andcreate the intimate interface necessary for exchange coupling. We establish aclear processing window; at temperatures below this window the desired softphase is not produced, while higher temperatures result in deleterious reactionat the soft/hard phase interfaces, causing an improper ratio of soft to hardphases. Improvements of Mr, Ms, and (BH)max are 42%, 29% and 37% respectivelyin the SrFe12O19/Fe3O4 composite compared to pure hard phase (SrFe12O19). Weprovide evidence of coupling (exchange spring behavior) with hysteresis curves,first order reversal curve (FORC) analysis and recoil measurements.

journal of materials chemistry. c

Synthesis of strontium ferrite/iron oxide exchange coupled nano-powders  with improved energy product for rare earth free permanent magnet  applications