Contribution of Additive Manufacturing of Rare Earth Material to the Increase in Performance and Resource Efficiency of Permanent Magnets

2018 ◽  
Vol 882 ◽  
pp. 135-141
Author(s):  
Nikolaus Urban ◽  
Alexander Meyer ◽  
Vitalij Keller ◽  
Jörg Franke
Keyword(s):  
Rare Earth ◽  
Additive Manufacturing ◽  
Permanent Magnets ◽  
High Energy ◽  
Significant Loss ◽  
Material Behavior ◽  
Parameter Study ◽  
Great Effort ◽  
Magnetic Performance ◽  
Process Route

Powerful permanent magnets are of essential meaning for electric drives as well as for environmental friendly energy conversion in general. The main requirements for these applications are high energy products, coercivity and remanent polarization, thermal stability as well as affordable price. As state of the art, rare earth permanent magnets, frequently consisting of NdFeB based alloys, meet these requirements. When complex geometric shapes like arcs, shells or freeform surfaces are required by the application, a trade-off has to be taken into account between magnetic performance and post magnet-fabrication processing steps. Either bonded magnets can be produced with great variety of geometries while accepting low magnetic performance due to a significant amount of nonmagnetic plastic binder matrix, or sintered blocks with great magnetic performance have to be machined out to the specified shape accepting great effort for grinding or wire cutting as well as a significant loss of valuable material. To overcome the drawback of both conventional established magnet manufacturing processes, Laser Beam Melting (LBM) is investigated to provide an alternative process route for magnet production. This innovative Additive Manufacturing (AM) process offers tool less production of nearly any thinkable geometry by use of a metal powder bed fusing process. Due to the challenging material behavior, a detailed parameter study is presented including a systematic design of experiment (DoE) approach. The connection between process parameters, density and key performance indicators on the B/H-curve is broken down.

Efficient near Net-Shape Production of High Energy Rare Earth Magnets by Laser Beam Melting

2017 ◽  
Vol 871 ◽  
pp. 137-144 ◽  
Author(s):  
Nikolaus Urban ◽  
Alexander Meyer ◽  
Sven Kreitlein ◽  
Felix Leicht ◽  
Jörg Franke
Keyword(s):  
Rare Earth ◽  
Laser Beam ◽  
Permanent Magnets ◽  
High Energy ◽  
Parameter Study ◽  
Efficient Production ◽  
Rare Earth Magnet ◽  
Laser Beam Melting ◽  
Near Net Shape ◽  
The Impact

In this publication we report on our progress in investigating the energy efficient production of rare earth permanent magnets by Laser Beam Melting in the powder bed (LBM). This innovative additive manufacturing process offers the potential to produce magnets of complex geometries without an energy intensive oven sintering step. Another advantage that increases the efficiency of this possible new process route is the high degree of material utilization due to a near net shape production of the magnets. Hence only little material is wasted during a post processing machining step. The main challenge in processing rare earth magnet alloys by means of LBM is the brittle mechanical behavior of the material and the change in microstructure due to the complete remelting of the magnet powder. We therefor expanded the parameter study presented in previous work in order to further increase relative density and magnetic properties of the specimens. In this context process stability and reproducibility could also be increased. This was achieved by investigating the impact of different exposure patterns and varying laser spot sizes. Simultaneously to the experiments the energy consumption of the LBM process was measured and compared with conventional rare earth magnet production routes.

Additive Manufacturing of Rare Earth Permanent Magnets: A Review on Laser Powder Bed Fusion (LPBF)

2021 ◽  
Author(s):  
Melissa Röhrig Martins Silva ◽  
Rafael Gitti ◽  
Rubens Nunes de Faria Jr. ◽  
fernando Landgraf ◽  
Cristiani Campos Pla Cid ◽  
...  
Keyword(s):  
Rare Earth ◽  
Additive Manufacturing ◽  
Permanent Magnets ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed

scholarly journals Additive manufacturing of heavy rare earth free high-coercivity permanent magnets

2020 ◽  
Vol 188 ◽  
pp. 733-739 ◽  
Author(s):  
A.S. Volegov ◽  
S.V. Andreev ◽  
N.V. Selezneva ◽  
I.A. Ryzhikhin ◽  
N.V. Kudrevatykh ◽  
...  
Keyword(s):  
Rare Earth ◽  
Additive Manufacturing ◽  
Permanent Magnets ◽  
High Coercivity ◽  
Heavy Rare Earth

scholarly journals Anisotropic characteristics and improved magnetic performance of Ca–La–Co-substituted strontium hexaferrite nanomagnets

2020 ◽  
Vol 10 (1) ◽  
Author(s):  
Jimin Lee ◽  
Eun Jae Lee ◽  
Tae-Yeon Hwang ◽  
Jongryoul Kim ◽  
Yong-Ho Choa
Keyword(s):  
Rare Earth ◽  
Magnetic Materials ◽  
Permanent Magnets ◽  
Microstructural Analysis ◽  
Strontium Hexaferrite ◽  
Strong Increase ◽  
Substitution Effects ◽  
Spray Pyrolysis Method ◽  
Magnetic Performance ◽  
The Cost

Abstract Recent studies on next-generation permanent magnets have focused on filling in the gap between rare-earth magnets and rare-earth-free magnets, taking into account both the cost-effectiveness and magnetic performance of the magnetic materials. As an improved rare-earth-free magnet candidate, here, Ca-substituted M-type Sr-lean hexaferrite particles within a nano- to micro-scale regime, produced using an ultrasonic spray pyrolysis method, are investigated. Theoretically, the maximum coercivity (Hc) can be achieved in submicron Sr-ferrite crystals (i.e., 0.89 μm). The plate-like resultants showed a significant enhancement in Hc, up to a record high of 7880.4 Oe, with no deterioration in magnetization (M: 71–72 emu/g). This resulted in more favorable magnetic properties than those of the traditional Sr–La–Co ferrites. On the basis of microstructural analysis and fitting results based on the law of approach to saturation method, the Ca-substitution effects on the change in size and anisotropic characteristics of the ferrite particles, including pronounced lateral crystal growth and a strong increase in magnetocrystalline anisotropy, are clearly demonstrated. The cost-effective, submicron, and Ca-substituted Sr-ferrite is an excellent potential magnet and moreover may overcome the limitations of traditional hard magnetic materials.

scholarly journals Prospects of additive manufacturing of rare-earth and non-rare-earth permanent magnets

2018 ◽  
Vol 21 ◽  
pp. 100-108 ◽  
Author(s):  
Vladimir Popov ◽  
Andrey Koptyug ◽  
Iliya Radulov ◽  
Fernando Maccari ◽  
Gary Muller
Keyword(s):  
Rare Earth ◽  
Additive Manufacturing ◽  
Permanent Magnets

scholarly journals Low Frequency Axial Flux Linear Oscillating Electric Drive Suitable for Short Strokes

2014 ◽  
Vol 2014 ◽  
pp. 1-5
Author(s):  
Govindaraj Thangavel
Keyword(s):  
Rare Earth ◽  
Permanent Magnets ◽  
Low Frequency ◽  
Weight Ratio ◽  
High Energy ◽  
High Energy Density ◽  
Axial Flux ◽  
And Control ◽  
Control Methodology ◽  
Good Agreement

The design, analysis, and control methodology of an energy efficient and high force to weight ratio rare earth N42 NdFeB based permanent magnet linear oscillating motor has been described. For this axial flux machine the mover is consisting of Aluminium structure embedded with rare earth permanent magnets of high energy density. Microcontroller based drive is developed for frequency and thrust control of the machine. Finite element method using FEMM is employed for analysis of various performance parameters of machine. The same parameters are also compared with the measured ones, which yields a good agreement to the proposed design.

scholarly journals SM-CO BASED MAGNETIC SYSTEM FOR 10 MEV TECHNOLOGICAL ELECTRON ACCELERATOR LU-10M

2018 ◽  
Keyword(s):  
Electron Beam ◽  
Rare Earth ◽  
Magnetic Flux ◽  
Electron Irradiation ◽  
Permanent Magnets ◽  
Magnetic System ◽  
Normal Component ◽  
Absorbed Dose ◽  
High Energy ◽  
Powder Metallurgy Method

Rare-earth permanent magnets are widely used in the accelerators of charged particles. However, the magnetic performance under irradiation remains a key issue for the most high energy applications such as accelerators with the energy up to 10 MeV. The aim of the work was to assess radiation and magnetic stability of Sm-Co and Nd-Fe-B permanent magnets under the direct electron irradiation with the energy of 10 MeV and bremsstrahlung. Sm-Co and Nd-Fe-B permanent magnets were produced by powder metallurgy method including PLP for the latter. The absorbed dose imposed by electron beam was 16 Grad (the total flux of electron per 1 cm2 was 1.4х1017) and 160 Grad. The radiation activity of both Nd-Fe-B and Sm-Co magnets was within the acceptable limits after the irradiation. This makes rare-earth magnetic materials suitable for such applications. In order to avoid overheating during electron irradiation, magnets were cooled with the water (T=38 °С). In order to estimate the changes in magnetic flux, the integral of the 3D interpolation normal component of magnetic flux was used. Calculated S parameter measured in arbitrary units was chosen as integrated z-component of magnetic flux. It was shown that magnetic flux of Nd-Fe-B magnets became 0.92 and 0.717 of initial values for 16 Grad and 160 Grad correspondingly, but the magnetic flux of Sm-Co magnets had no change to the same absorbed doses. Thus, Sm-Co magnets were chosen for simulating and designing magnetic system for electron beam analysis of a technological accelerator with energy up to 10 MeV. The distance between the poles of the magnet was 25.25 mm. The highest magnetic field inside the magnetic system was 0.3110 T. The effective distance was 33.53 mm. The measured parameters of the magnetic system based on Sm-Co magnets agreed with the simulation experiment. Magnetic system can also be used to adjust the accelerator in the energy range up to 10 MeV.

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