Hard-soft magnetic nanocomposite magnets hold great promise for next-generation permanent magnets due to their ultrahigh theoretical maximum energy product ((BH)max) and low-cost, while the low coercivity (Hc) of the currently fabricated SmCo/FeCo nanocomposites limits their performance. In this work, two types of microstructures with and without direct contacts between soft and hard magnetic phases in nanocomposites were designed and analyzed by micromagnetic simulations. The results showed that the directly contact nanocomposites exhibit a larger magnetic domain size and stronger interphase exchange coupling, facilitating magnetization of the hard magnetic phase and impeding reversal of the soft magnetic phase during magnetization and demagnetization processes. The simulation results were validated through the fabrication of SmCo/FeCo nanocomposites featuring an in-situ formed semi-coherent soft/hard magnetic phase. This nanocomposite was synthesized by crystallizing an as-milled amorphous Sm-Co-Fe precursor derived from a Sm-Co-Fe ingot. A reference magnet of without soft/hard magnetic phase contact, i.e. with amorphous-separated between two phases was fabricated by crystallizing amorphous-nanocrystalline precursor from co-milling Sm-Co alloy and Fe powders. Comparatively, the semi-coherent contact nanocomposite magnet showed a 28% increase in Hc and an 18% improvement in (BH)max. Microstructural analysis revealed that the semi-coherent structure forms through synchronous crystallization driven by a compositional gradient. Micromagnetic simulations, Henkel curves, and in-situ domain observations confirmed that enhanced exchange coupling is the origin of Hc enhancement. This work provides a viable microstructural regulation strategy for developing high-performance nanocomposite magnets.
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