WP2 “Improved process routes for resource-efficient permanent magnet”: A reference alloy composition has been successfully designed. It both meets CRF’s requirements for recycled magnets, and the high performance needed by the high-end market (automotive premium). Due to delays in the commissioning of a new pilot line equipment, reference magnets made out of virgin raw materials and production of proof-of-concept recycled magnets were done in existing lines. The magnetic properties of these proof-of-concept recycled magnets are encouraging and demonstrate the potential of the MAGELLAN approach. To qualify the magnetic properties of the manufactured magnets, the reference magnets were analysed with an inter-laboratory cross-characterisation to establish a baseline for the further systematic characterisation of MAGELLAN magnets.
WP3 “Improved magnet & motor design towards recycling": The high-end EDM 800V Motor was selected based on performance, applicability and market relevance. Motor internal drawings could not be provided, so a digital twin from bibliographical work were set up and simulations were started. Two motors were disassembled for reverse engineering which provided better information on the geometries of the rotor, stator and on the magnet sizes, magnetics characteristics and compositions. A reference EVTM digital twin was developed and is ready to receive information from different recycled PM batches to test and initiate the designing of the rotor with PIM PM with the objective to reduce PM mass per kW. The reference and recycled PM manufacturing drawings were provided, and sent for manufacturing. The process flow and design rules to produce near-net-shape magnets by Powder Injection Molding process were defined.
WP4 “Recycling of EoL PM Magnets containing Heavy Rare Earth Elements”: thanks to a strong mobilization of the consortium, 40 kg of PMs from motors of e-scooters and e-bikes were extracted. Additionally, rotors of 22 EoL electric or hybrid cars motors were recovered with an average PM mass estimated at about 1 kg per rotor. The thermomechanical extraction of PMs is currently ongoing. Preliminary plasma melting tests with magnets from mixed industrial uses and with demagnetised PMs from e-scooters were done. In parallel, to determine the best magnet-to-alloy short-loop recycling process, partners started to benchmark the plasma melting route and the induction melting route.
WP5 “Validation of Sustainability and Responsibility of the MAGELLAN solution for PMs”: Studies of the current value chains of REE from both secondary and primary sources show that the current collection methods and the volumes available for recycling are uneconomical and require regulatory support. For the LCA of the MAGELLAN value chain, baseline calculations for the current method of high performance PM production were created. A study on the sustainability of the REE production from mining and EoL products was conducted, which will be used to create sustainability guidelines for the MAGELLAN solution.
WP6 “Demonstration of the MAGELLAN solution for highly recyclable permanent magnets in an EVTM”: Activity was anticipated to take advantage of the reference EVTM availability. They were disassembled and the testing bench adaptation parts were designed and manufactured in order to make the equipment ready for reference EVTM testing. Two reference EVTM were provided for instrumentation and testing to establish the reference results for comparison with MAGELLAN recycled and PIM magnet equipped rotors later in the project.
