As giant magnetostrictive materials with low magnetocrystalline anisotropy, Tb-Dy-Fe alloys are widely used in transducers, actuators and sensors due to the effective conversion between magnetic energy and mechanical energy (or acoustic energy). However, the intrinsic brittleness of intermetallic compounds leads to their poor machinability and makes them prone to fracture, which limits their practical applications. Recently, the addition of a fourth element to Tb-Dy-Fe alloys, such as Ho, Pr, Co, Nb, Cu and Ti, has been studied to improve their magnetostrictive and mechanical properties. This review starts with a brief introduction to the characteristics of Tb-Dy-Fe alloys and then focuses on the research progress in recent years. First, studies on the crystal growth mechanism in directional solidification, process improvement by introducing a strong magnetic field and the effects of substitute elements are described. Then, meaningful progress in mechanical properties, composite materials, the structural origin of magnetostriction based on ferromagnetic MPB theory and sensor applications are summarized. Furthermore, sintered composite materials based on the reconstruction of the grain boundary phase also provide new ideas for the development of magnetostrictive materials with excellent comprehensive properties, including high magnetostriction, high mechanical properties, high corrosion resistance and high resistivity. Finally, future prospects are presented. This review will be helpful for the design of novel magnetostrictive Tb-Dy-Fe alloys, the improvement of magnetostrictive and mechanical properties and the understanding of magnetostriction mechanisms.

In Tb-Dy-Fe alloy systems, Tb_0.29Dy_0.71Fe_1.95 alloy shows giant magnetostrictive properties under low magnetic fields, thus having great potential for transducer and sensor applications. In this work, the lattice parameters of Tb_0.29Dy_0.71Fe_1.95 compounds as a function of a magnetic field were investigated using in situ X-ray diffraction under an applied magnetic field. The results showed that the c-axis elongation of the rhombohedral unit cell was the dominant contributor to magnetostriction at a low magnetic field (0–500 Oe). As the magnetic field intensity increased from 500 Oe to 1500 Oe, although the magnetostrictive coefficient continued to increase, the lattice constant did not change, which indicated that the elongated c-axis of the rhombohedral unit cell rotated in the direction of the magnetic field. This rotation mainly contributed to the magnetostriction phenomenon at magnetic fields of above 500 Oe. The structural origin of the magnetostriction performance of these materials was attributed to the increase in rhombohedral lattice parameters and the rotation of the extension axis of the rhombohedral lattice.

In Tb-Dy-Fe alloy systems, Tb_0.29Dy_0.71Fe_1.95 alloy shows giant magnetostrictive properties under low magnetic fields, thus having great potential for transducers, microsensors, and other applications. The C15 cubic crystal structure of Tb-Dy-Fe has long been thought to be the source of giant magnetostriction. It is surprising that such a highly symmetrical crystal structure exhibits such a large magnetostrictive strain. In this work, the lattice parameters of Tb_0.29Dy_0.71Fe_1.95 magnetostrictive materials were studied by processing atomic-resolution images. The selected area diffraction patterns show a face-centered cubic structure, but the fast Fourier transform diagram shows that the cubic structure has obvious distortion. The lattice parameters obtained by geometric phase analysis (GPA) and Gaussian model-based fitting and calculation show that the lattice constants a, b, and c are not strictly equal, and small disturbance of the lattice constants occurs based on the cubic structure. The actual crystal structure of the Tb-Dy-Fe material is a slightly disturbed cubic structure. This variation in the crystal lattice is mainly caused by the inhomogeneous composition and may be related to the giant magnetostrictive properties of Tb-Dy-Fe alloy.