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Alloys of Nd10Fe85B5, Nd12Fe82B6, and Nd14Fe79B7 were melted and then solidified under the containerless state using a drop tube. In the as-dropped sample, a large amount of the Nd2Fe17Bx was contained as a metastable phase. Particularly in relatively large samples, the metastable phase, which was partially decomposed into the Nd2Fe14B and a-Fe phases, shows a microstructure similar to that of normalized low-carbon steel. The heat treatment of the as-dropped samples induces a dual- stage phase transformation. The 1st stage of the phase transformation, which is dominant in the Nd14Fe79B7 alloy, is the diffusive phase transformation from Nd2Fe17Bx and Nd-rich phases into the Nd2Fe14B phase at 950 K, and the 2nd stage of the transformation, which is dominant in the Nd10Fe85B5 alloy, is the decomposition of the metastable phase into the Nd2Fe14B and a-Fe phases at 1100 K. Although the rate of the phase transformation in either stage is controlled by the diffusion of Nd atoms, the diffusivity at the 1st stage of the phase transformation, being large due to the existence of the Nd-rich phase adjacent to the Nd2Fe17Bx phase, results in a decrease in transformation temperature

Heat treatment of metastable Nd2Fe17Bx phase formed from undercooled melt of Nd–Fe–B alloys