The exchange coupling between a hard magnetic layer MnBi and a soft magnetic layer Co-Fe has been found to significantly improve the maximum energy product. In this work, the spin structure of exchange-coupled MnBi:Co-Fe bilayers is experimentally investigated by X-ray magnetic circular dichroism (XMCD) and polarized neutron reflectometry (PNR). We find that the out-of-plane magnetization reversal process of the MnBi:Co-Fe bilayer structure involves formation of a curling-type twisting of the magnetization in the film plane at low or intermediate reversal fields. Micromagnetic simulations are further performed to provide a detailed view of the spins at the curling center. Reminiscent of chiral spin structures known as spin bobbers, this curling in the exchange-coupled hard-soft magnetic bilayers is a new type of skyrmionic spin structure and worth further investigation.

We demonstrate substantial enhancement in the energy product of MnBi-based magnets by forming robust ferromagnetic exchange coupling between a MnBi layer and a thin CoFe layer in a unique perpendicular coupling configuration, which provides increased resistance to magnetization reversal. The measured nominal energy product of 172kJ/m3 at room temperature is the largest value experimentally attained for permanent magnets free of expensive raw materials. Our finding shows that exchange-coupled MnBi/CoFe magnets are a viable option for pursuing rare-earth-free magnets with energy products approaching those containing rare-earth elements.