Permanent magnets constitute a very important industrial
market where, currently, Japan is by far the world leader
in the production of these magnets controlling more than
50% of the world market, including the highly competitive
U.S. market. Among these, hard ferrites are the most
common material used (around 90% by tonnage of the total
market) due to their very attractive price, good
performance and cheap and non strategic raw materials
Powder Injection Moulding (PIM) has only recently
started to be applied successfully to the production of
soft magnets thanks to recent innovations in moulding
machine technology. Surprisingly enough, no such research
effort has been done with hard sintered ceramic magnets
even though there is a vast market for permanent magnets
for motors. A possible explanation lies in the high
expectations on price reductions of competing rare earth
permanent magnets, namely Nd Fe B which have, so far,
not been fulfilled.
The main objective of the project consists in
manufacturing hard ferrite sintered magnets with complex
shapes in a single step by PIM. The main objectives are:
Apply PIM technology to obtain injection moulded hard
ferrites magnet prototypes with high magnetic
Increase the homogeneity within the volume of the
component by 40%.
Eliminate machining operations.
Develop and optimize new feedstock formulations for
hard ferrite injection moulding to facilitate injection
and improve magnetic and structural characteristics.
Design and construct injection moulds incorporating
magnetic coils to permit magnetic filler
orientation during moulding.
Develop computer tools to study the magnetic field,
intensity and distribution, inside the injection mould
and tailor injection moulding software to simulate the
injection of feedstock with hard ferrite fillers to
reduce the design to manufacture cycle time.
Funding SchemeCSC - Cost-sharing contracts
20009 San Sebastian