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.
