SINGLE-GRAIN RE-ENGINEERED ND-FE-B PERMANENT MAGNETS

Project Information

GREENE

Grant agreement ID: 101129888

DOI

10.3030/101129888

EC signature date 26 April 2024

Start date 1 June 2024

End date 31 May 2028

Funded under

• Digital, Industry and Space

Total cost

€ 7 999 972,50

EU contribution

€ 7 999 972,50

Coordinated by

INSTITUT JOZEF STEFAN
Slovenia

Periodic Reporting for period 1 - GREENE (SINGLE-GRAIN RE-ENGINEERED ND-FE-B PERMANENT MAGNETS)

Reporting period: 2024-06-01 to 2025-11-30

Summary of the context and overall objectives of the project

Permanent magnets based on rare-earth elements, such as neodymium iron boron (Nd Fe B), have outstanding magnetic properties and are critical for Europe’s green and digital transition: they are essential components of wind turbines, electric vehicles, and countless other devices. Yet, Europe relies heavily on imports for rare earths and magnetic materials, and conventional production has significant environmental impacts. At the same time, the intrinsic properties of these magnets are not yet fully exploited, leaving room for optimisation. GREENE tackles these issues by developing Single Grain Re Engineered Nd-Fe-B permanent magnets with a novel grain boundary phase and interface, allowing for a reduction of rare earth content while improving performance and recyclability. To achieve this, the project integrates advanced modelling, the creation of feedstocks from fresh and recycled material, surface and interface engineering, novel production methods, pilot line validation, life cycle/techno economic assessment, outreach activities and skills development.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Theoretical understanding & modelling: In the first period, GREENE partners established a comprehensive, multiscale framework for the sustainable development and optimisation of Nd-Fe-B permanent magnets, integrating requirements analysis, modelling, first-principles calculations, machine learning and data assimilation.

Feedstock from fresh and recycled sources: A reliable method for growing single crystals was developed and first atomic-scale studies of pristine surfaces implemented. Recycled and fresh micro-/nanocrystalline powders were produced with low oxygen content, providing the structurally and chemically controlled material basis required for later interface design, consolidation and performance optimisation.

Engineering grain boundaries and model interfaces: Building on modelling results and the feedstocks developed, model interfaces were established. In addition, precursors for interface and grain boundary engineering were developed and concepts transferred to realistic feedstock, establishing controlled starting materials for grain-boundary modification and subsequent consolidation. Enabling infrastructure (a glove-box integrated coating system) was delivered.

Magnet manufacturing: In the first period, conventional and unconventional fast sintering strategies for fresh and recycled powders were investigated and the microstructure-property relationships established. Optimisation pathways for fast, resource efficient magnet manufacturing were defined to be fed back to interface engineering and feedstock development.

Developing advanced characterisation: Interface structure, texture and domain behaviour were analysed, directly feeding back to modelling and process optimisation.

Production line: In the first period, progress was made in developing integrated alloy, powder and magnet production capabilities for both recycled and fresh materials. Work also advanced on the planning of the GREENE beta prototype magnet production line. Core equipment has been installed, and industrial-scale trials have been carried out.

Life cycle and techno-economic assessment: The baseline Life Cycle Assessment for conventionally sintered Nd-Fe-B magnets was established, mapping the full production chain and identifying key environmental hotspots. A detailed process flow and updated Life Cycle Inventory supported modelling of three alloy scenarios, with impacts assessed across 16 categories. The expected GREENE production routes for future prototypes were also defined.

Building skills: Based on a skills gap mapping, GREENE partners implemented a range of capacity building activities, including lectures, researcher exchanges, secondment visits, workshops, and public science events. Educational materials helped translate complex science into accessible content for a broader audience.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

GREENE aims to push the boundaries of current knowledge and practice in permanent magnet science, manufacturing, and sustainability. The project seeks to demonstrate that permanent magnets can be designed, produced and scaled with substantially lower overall rare earth content while maintaining or even enhancing their performance and recyclability. GREENE therefore moves beyond incremental improvements and lays the groundwork for a new generation of resource efficient, digitally guided magnet technologies.

New insights into the structural and magnetic properties and underlying mechanisms will advance the digital transformation of European materials and magnet producers and help create strategic innovation markets driven by advanced materials. To fully realise this potential and maximise impact, further research is necessary.

Novel magnetic composition and advanced materials for re-designed high-performance permanent magnets, offering easier recyclability and longer enhanced lifecycles, are key to building a sustainable European permanent magnets value chain with lower toxicity and a reduced carbon footprint. To ensure these innovations reach the market and deliver their full impact, patenting, market and finance access, commercialisation and a supportive regulatory environment are essential.

Enhanced capacities for producing more sustainable high-performance permanent magnets with reduced RE content will increase the competitiveness and sustainability of magnet manufacturing, supporting the green transition, strengthening strategic autonomy and contributing to a more resilient European industry. Achieving these benefits will require further upscaling, including additional funding, effective commercialisation pathways and a supportive regulatory environment.

A strategy for skills informed by a mapping of existing gaps and targeted capacity-building activities can support Europe in reclaiming its position as a major player in the permanent magnets market, safeguarding economic prosperity and creating job opportunities. To fully realise these benefits, further upscaling supported by additional funding will be essential.

The GREENE Project in a nutshell

GREENE Background Visual