Project description
Additive manufacturing for magnet production for Electric vehicles
Amid efforts to reduce emissions and enhance sustainability, the burgeoning electric vehicle industry, along with the rising demand for batteries and magnets, has placed considerable strain on the magnet industry. In this context, the EU-funded MagNEO project aims to address this challenge by developing a resilient and sustainable solution for REE-free permanent magnet (PM) production, catering to the mobility sector and other emerging applications. Leveraging additive manufacturing and a range of innovative methodologies, materials and compositions, the project seeks to enable efficient, sustainable, and precise magnet manufacturing. Through demonstrations and in-depth analysis, it aims to enhance scalability in collaboration with experts and specialists.
Objective
MagNEO's objective is robust and sustainable REE-free permanent magnets (PM) for emergent energy & mobility applications. The concept hinges upon novel compositions of AlNiCo & HEAs undergoing similar spinodal decompositions, processed by additive manufacturing (AM). The recycling strategies developed will allow environmentally friendly repurposing of disparate metallic constituents, with emphasis on Co recovery. The targeted properties of the new PMs are (BH)max ≥60 kJ/m3 for Co ≤24% and (BH)max ≥72 kJ/m^3 for Co≤35%.
MagNEO will be realised through the following strategies: 1) open-source modelling tools, machine learning guided high-throughput digital & experimental screening to accelerate the development of novel environmentally benign materials, with compositions suitable for AM, throughout multicomponent alloy phase spaces, 2) harness the competitive advantages conferred by AM, such as shape complexities and microstructure engineering, in tandem with comprehensive heat treatment. These will be crafting novel anisotropic microstructures characterized by higher coercivity, culminating in (BH)max values exceeding 60 kJ/m^3.
The performance of the new PMs will be verified for a) low-speed PM generators in wind turbines & ship propulsion shafts, (b) high speed (>100 m/s) rotors in heat pumps and (c) ABS sensors & headlight systems in automotive. The upscaling process will be conducted through techno-economic analyses performed by the manufactures in synergy with the end-users. This procedure will begin with a proof of concept at TRL3-4 and will culminate with technology validation at TRL6.
MagNEO stands out as a fusion between accomplished multidisciplinary experts who will contribute to training and joint actions with other European teams to increase the competitiveness and sustainability of European industry by bringing innovative materials and new methods closer to the market, while maintaining cost-effectiveness of REE-free products in consideration.
Fields of science
- engineering and technologyenvironmental engineeringwaste managementwaste treatment processesrecycling
- engineering and technologyenvironmental engineeringenergy and fuelsrenewable energywind power
- engineering and technologyelectrical engineering, electronic engineering, information engineeringelectronic engineeringsensors
- engineering and technologymechanical engineeringmanufacturing engineeringadditive manufacturing
- natural sciencescomputer and information sciencesartificial intelligencemachine learning
Programme(s)
Funding Scheme
HORIZON-RIA - HORIZON Research and Innovation ActionsCoordinator
7034 Trondheim
Norway