In this study, low-iron Zn–Fe alloy coatings and pure Zn coatings, with or without trivalent chromium passivation treatment, were electrodeposited onto a sintered NdFeB magnet from a weak acid chloride bath. The surface morphology and structure of the coatings were then examined using the X-ray diffraction, a scanning electron microscope and 3D white-light interfering surface analysis. Meanwhile, the electrodeposition behavior and anti-corrosive properties of the coatings were investigated using cyclic voltammetry, potentiodynamic polarization, electrochemical impedance spectroscopy, and natural salt spray tests. The results indicate that a passivated Zn–Fe alloy coating with a 0.9 wt.% Fe content provided much better corrosion resistance than a pure Zn coating and could provide both anodic protection and physical barrier function in the NdFeB substrates. The Fe element in Zn–Fe alloy coating was predominantly in solid solution in η-phase and small amounts in elemental form, which was beneficial to acquire a compact coating and passivation film. Finally, the passivated Zn–Fe alloy coating withstood 210 h against a neutral 3.5 wt.% NaCl salt spray without any white rust, which was 3–4 times longer than the pure Zn coating.

Developing permanent magnets based on full high abundance rare-earth (RE) elements of Ce, La, and Y offers tremendous potential for the balanced utilization of RE resources, but the magnetic properties of these magnets are restricted due to the magnetic dilution caused by the existence of the paramagnetic REFe2 laves phase. Herein, the non-RE element Ge with high efficiency was introduced to enhance the magnetic performance of Ce-, La-, and Y-based RE–Fe–B nanocrystalline alloys, and the highest maximum energy product [(BH)max] of 65.6 kJ/m3 and an enhanced coercivity (Hcj) of 346 kA/m were achieved in the [(Ce0.8La0.2)0.5Y0.5]16Fe77.5B6Ge0.5 alloy. This improvement is attributed to the increased content of the hard magnetic RE2Fe14B phase with refined grain size, which is further confirmed by micromagnetic simulation. First-principles calculations and a microstructure analysis reveal that the laves phase is effectively suppressed by Ge addition due to the formation of the Ce5Ge3 phase with the lowest formation energy. This work clarifies the positive role of Ge in simultaneously enhancing the Hci and (BH)max of nanostructured (Ce,La,Y)–Fe–B alloys.