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.
