Periodic Reporting for period 1 - MagNEO (MagNEO: Advanced additively manufactured permanent Magnets for New Energy and MObility Applications)
Berichtszeitraum: 2024-05-01 bis 2025-10-31
Europe is entering a decisive phase in its transition to renewable energy and sustainable mobility, as outlined in the European Green Deal, Fit-for-55, and REPowerEU. Technological and socioeconomical aspects in application fields such as wind turbines, ship propulsion systems, heat pumps, and electric vehicles are central to this new energy landscape, yet at their core lies a strategic vulnerability: the permanent magnet. Today, over 98% of rare-earth-element (REE) based magnets are produced in China, creating a critical supply-chain dependency that risks Europe’s industrial resilience and technological sovereignty. MagNEO addresses this challenge by developing high-performance, REE-free permanent magnets based on novel AlNiCo compositions that outperform current materials of the same family. By combining multiscale modelling, machine learning, and high-throughput synthesis, the project accelerates alloy design and establishes processing routes aiming at delivering magnets with (BH)max above 60 kJ/m³ while reducing cobalt content. Sustainability is central to MagNEO: recycling strategies will recover critical metals and extend magnet lifetimes, supporting EU circular economy objectives. The project’s outcomes will be validated in end-user demonstrators, including low-speed generators, high-speed rotors, and automotive ABS sensors and headlight systems. By enabling REE-free magnets at TRL 6, MagNEO aims at enhancing Europe’s industrial autonomy, reducing import dependence, and unlocking market opportunities estimated at €6.5 billion by 2030, while ensuring adoption aligns with societal and environmental expectations.
During the first 18 months, the project advanced across alloy development, powder production, additive manufacturing (AM), modelling, application analysis, and sustainability work. A multiscale methodology was developed to identify AlNiCo-based compositions and microstructures with tailored micro and nanoscale geometries, enhancing magnetic anisotropy. High-throughput arc melting synthesis was combined with advanced characterization (SEM, TEM, X-ray dispersive spectroscopy, micro/nano electron diffraction) and modelling at quantum mechanical, micromagnetic, thermodynamic, and microstructural levels. This approach enabled the study of numerous arc-melted alloys and revealed several promising compositions with Co contents below 24 wt%, now under experimental validation. Cracking issues in AM were also investigated. Modelling supported powder atomization, AM microstructure evolution, and electric machine behaviour. Simulations guided the design of a new atomizer nozzle, identified parameters affecting powder quality, and defined critical LPBF conditions. System-level simulations assessed how material properties and geometries influence generator and motor performance.
AlNiCo 5, AlNiCo 8, and modified alloys were successfully atomized, and LPBF processing windows achieving 95–98% density were established, though cracking persists. Initial thermomagnetic treatments (TMT) on LPBF samples highlighted the need for further optimization. WP4 advanced recycling by identifying waste streams and sourcing end-of-life (EoL) AlNiCo magnets. These were crushed and compounded with polymer matrices to produce filaments and granulates for FFF and FGF, achieving high loading fractions of 70% and 82%. Selective recovery of critical metals from EoL magnets and other waste streams is planned. Sustainability and socio-technical activities began in Month 12. A state-of-the-art assessment of environmental and cost impacts was completed, LCA/LCC data collection is ongoing, and socio-technical analysis progressed through literature review, protocol development, and initial interviews. Application-oriented work defined magnet requirements for key industrial cases. End-user data-enabled specifications for a MW class shaft generator, a high-speed motor for heat pumps, and a claw stepper motor for automotive lighting. Technical data collection and comparative model analysis identified the required magnetic properties and produced complete technical descriptions. Representative machine models were established to guide upcoming validation and optimization. Overall, the project has built a strong technical foundation across synthesis, modelling, powder production, AM, recycling, and application analysis, preparing the next phase focused on composition refinement, improved LPBF routes, and system-level validation.
AlNiCo 5, AlNiCo 8, and modified alloys were successfully atomized, and LPBF processing windows achieving 95–98% density were established, though cracking persists. Initial thermomagnetic treatments (TMT) on LPBF samples highlighted the need for further optimization. WP4 advanced recycling by identifying waste streams and sourcing end-of-life (EoL) AlNiCo magnets. These were crushed and compounded with polymer matrices to produce filaments and granulates for FFF and FGF, achieving high loading fractions of 70% and 82%. Selective recovery of critical metals from EoL magnets and other waste streams is planned. Sustainability and socio-technical activities began in Month 12. A state-of-the-art assessment of environmental and cost impacts was completed, LCA/LCC data collection is ongoing, and socio-technical analysis progressed through literature review, protocol development, and initial interviews. Application-oriented work defined magnet requirements for key industrial cases. End-user data-enabled specifications for a MW class shaft generator, a high-speed motor for heat pumps, and a claw stepper motor for automotive lighting. Technical data collection and comparative model analysis identified the required magnetic properties and produced complete technical descriptions. Representative machine models were established to guide upcoming validation and optimization. Overall, the project has built a strong technical foundation across synthesis, modelling, powder production, AM, recycling, and application analysis, preparing the next phase focused on composition refinement, improved LPBF routes, and system-level validation.
The first 18 months have built a solid foundation, with early results confirming the potential of the project’s technological directions. A methodology combining theoretical work and characterization in WP1 shows a promising path toward higher-performance AlNiCo magnets with reduced Co content, supporting rare-earth-free solutions. Modelling in WP1–WP2 delivered major advances, including a conical nozzle design, predictive AM frameworks, and system-level analysis tools for electric machines. These results guide the next phases and will benefit from experimental validation, broader datasets, and industrial input. Activities in powder production, AM, recycling, and sustainability are progressing steadily. WP3 is preparing upcoming AM and recyclability experiments, while WP4 has completed an initial literature-based environmental assessment, informing later LCA/LCC work. WP5 has defined technical specifications, identified current limitations, and outlined improvement actions to ensure alignment with industrial needs. Overall, early achievements show strong experimental and modelling progress and position the project well for the next stage, where continued research, demonstration activities, and industrial engagement will be key to achieving broader impact.