Effects of dimension of a cylindrical crucible (
D/
L), temperature, excess metallic Ca and salt ratio on the preparation of Nd-Fe alloys from NdF
3-Ca-CaCl
2-Fe reaction mixtures have been investigated. The alloy was formed on the bottom of the crucible as well as along the periphery due to creeping action of excess Ca metal on the inside wall of the mild steel crucible. In order to minimize the alloy formation along the periphery and to improve the process efficiency, the following condition was found to be optimum:(1) the ratio,
D/
Lat 1.0, (2) at a temperature of around 860°C, (3) with 5 mole % excess Ca, and (4) salt ratio, the amount of CaCl
2per gram of the stoichiometric Nd in the NdF
3, at 1.15. Under the above condition, the Nd recovery in the alloy formed on the crucible bottom was 98.5% and composition by weight of the alloy was as follows: 17.2% Fe, 0.42% Ca, 0.02% oxygen, 0.048% C, <0.01% nitrogen and<0.02% chlorine. The small quantity of residual Ca was removed to a trace amount by vacuum arc melting.
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