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Content archived on 2024-06-11

European Magnets with Enhanced Remanence for Greater Efficiency

Objective



Objectives and content

In the field of permanent magnets there is a need for a magnet whose performance and price is intermediate between low-cost low-performance ferrites and high-cost high- performance Nd-Fe-B sintered magnets. Such a mid-range magnet would find applications in many sectors including consumer electronics, computer peripherals and the automobile industry. There already exists a magnet which partially meets these requirements. It is a bonded magnet made from melt-spun Nd-Fe-B ribbons, termed MQ1. Due to the isotropic character of the material the remanence of such magnets is limited to 0.8 T. In additions the price of this material is high due to the fact that its production is entirely controlled by a monopoly.

Philips has a patent on another type of material [p1] whose heterogeneous microstructure consists of magnetically soft grains (mainly Fe3B) and magnetically hard grains (Nd2Fel4B). The crystallites are very small and exchange-coupled leading to the phenomenon of remanence enhancement and remanences as high as 1.2 T may be reached. At present, the coercivity of this material is not sufficiently high to use it for most applications.
The aim of this project is to optimise a hard magnetic material in order to develop a new type of bonded magnet with a time to market after the completition of the project of 12 - 18 months. To achieve this, the following objectives are defined: i) to improve the properties of hard magnetic powders of the type Nd4.5Fe77B18.5 to bulk values in the range of Jr = 1.2 T with JHc = 0.4 MA / m to Jr = 1.0 T with JHc = 0.6 MA / m; ii) to make a bonded magnet with such rapidly quenched materials with a BHmaX in the range of 50 - 80 kJ / m3 with an expected industrial cost of 55 ECU / kg; iii) to test the performance of such a magnet in a demonstrator.

The proposed workplan is:
i) To improve the properties of this enhanced-remanence material by - performing a systematic study of the influence of substitutions and additives on the parent composition and on the processing conditions.; - by characterising the microstructural and magnetic properties; - by studying coercivity mechanisms and by performing analytical and 3D numerical simulations;
ii) To optimise the bonding process for such magnets by first performing compaction bonding and at a later stage injection bonding;
iii) To conceive a suitable application (demonstrator) for such a bonded magnet and to critically characterise the performance of the magnet in the application.

The project will be conducted in three phases: coarse selection phase, fine selection phase and demonstration phase. After completion of the first phase, the project will be critically analysed and a go/no-go decision will be taken. The project associates three industrial partners with complementary activities (supplier. manufacturer and end user) with three academic partners with recognised competencies in their respective fields (materials, intrinsic and extrinsic magnetic properties and modelling).

In summary, this project intends to exploit Europeanl intellectual property by combining European industrial and acdemic expertise in order to respond to a current market need and lead to the realisation of a more efficient, lower cost magnet which promotes energy efficient applications.

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Coordinator

RHODIA Chimie SA
EU contribution
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Address
18 avenue d'Alsace
92097 Paris la Défense
France

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Participants (5)

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