Recently,
recycling of severely contaminated Nd–Fe–B
sintered magnets sludge had drawn considerable attention due to the
concern of environmental burden and high cost of traditional wet process
recycling. In the present study, we describe a new technology that
utilizes distillation, reduction–diffusion (RD), and nanoparticle-doping
techniques to prepare recycled Nd–Fe–B sintered magnets
from Nd–Fe–B sludge in an efficient and environmentally
friendly way. The sludge was purged first to remove both organic impurities
and nonmagnetic impurities. The purged products were then treated
with calcium-assisted RD reaction to obtain Nd2Fe14B single-crystalline powders. After doping with NdH
x
or DyH
x
nanoparticles, the powders
were fabricated into recycled Nd–Fe–B sintered magnets
by the conventional sintering method. The recycled magnets bear comparable
magnetic properties to the original magnets. With 10% doping of NdH
x
, the energy product of the original magnets
is recovered by 88%; with 15% doping of DyH
x
, the coercivity of the recycled magnets increases by 34% compared
to the original magnets. Furthermore, comparison between the conventional
recycling method and our new technology demonstrates that our new
technology is an economical and environmentally friendly strategy
for sintered Nd–Fe–B sludge recycling.