Objective
To develop new high performance permanent magnets of the type Nd-Fe-B for use in electric motors for vehicular application and for other industrial applications. Specifically, this project concentrates on the permanent magnets to be used in future hybrid electric vehicles (large magnets, high magnetic properties) and advanced car accessories (small magnets, medium magnetic properties).
The project was as follows:
the preparation and characterisation of related magnetic alloys, with improved properties and processing, compared to existing ferrite based magnets; the characterisation of the magnetic formulations through a study of the relationship between magnetic microstructure and magnetic properties; the development of magnetic components using new manufacturing systems.
The scientific and technical aims of the project included analysis of the impact of the new magnets on the features of the electric motors, definition of new concepts for the design of such motors and identification of the manufacturing processes of the permanent magnets, suitable for production at industrial level. The technology included: model calculations for determining the optimum geometry and magnetic properties of component magnets; powder metal sintering and melt spinning polymer bonding for the manufacturing process; electrochemical methods and Mossbauer spectroscopy for studying corrosion behaviour and high temperature oxidation kinetics; development of processing routes for Nd-Fe-B permanent magnets. Progress has been made in corrosion protection, thermal stability and development of cost effective production processes.
A process has been developed for manufacturing polymer bonded magnets based on the new material neodymium (15) iron (77) boron (8). The received material was crushed and melted under argon. The melt was squirted onto a fast rotating water coled roller can converted into magnetizable ribbons. The ribbons were ball milled into a fine powder and mixed with a phenobic formaldehyde resin in the volume ration 2 to 1. The mixture was moulded at 60 kg cm{-2} and cured by ultrasound with a process time of approximately 10 S. An unrestrained postcuring at 150 C for 3 hours developed the full dimensional stability. The magnets were corrosion protected by a 2 component epoxy lacquer although internal protection through additives in the resin was considered. This process for making polymer bonded magnets is advantageous compared to known processes. The loading of magnetizable material can be much higher than in traditional viscosity limited processes. The process can be fully automated and high productivity can be obtained. The process can be further optimized especially by curing under an applied magnetic field. The corrosion behaviour of neodymium iron boride type magnets with different additives has been investigated using various techniques.
THE PROJECT BRINGS TOGETHER ELECTRIC MOTOR VEHICLE AND MAGNET INDUSTRIES. THE WORK IS CARRIED OUT IN A NUMBER OF PHASES :
- THE PREPARATION, CHARACTERISATION AND EVALUATION OF RELATED MAGNETIC ALLOYS WITH IMPROVED PROPERTIES AND PROCESSING.
- THE CHARACTERISATION OF MAGNETIC COMPONENTS THROUGH A STUDY OF THE RELATIONSHIP BETWEEN MAGNET MICROSTRUCTURE AND MAGNETIC PROPERTIES.
- NEW ELECTRICAL MOTORS CONCEPTS AND MAGNETIC COMPONENTS SPECIFICATIONS, TO CHECK WITH PRACTICAL TESTING EVALUATION AND SYSTEM ECONOMICS.
- THE DEVELOPMENT OF MAGNETIC COMPONENTS ON THE BASIS OF ECONOMICAL INDUSTRIAL MANUFACTURING PROCESSES.
THE SCIENTIFIC AND TECHNICAL AIMS OF THE PROJECT COVERS THE FOLLOWING AREAS :
- ANALYSIS OF THE IMPACT OF THE PERMANENT MAGNETS, TYPE ND-FE-B, ON THE TECHNICAL AND ECONOMICAL FEATURES OF ELECTRIC MOTORS.
- DEFINITION OF NEW CONCEPTS FOR THE DESIGN OF SUCH MOTORS.
- DEFINITION OF THE MATERIAL CHARACTERISTICS OF THE PERMANENT MAGNETS.
- IDENTIFICATION OF THE MANUFACTURING PROCESSES OF THE PERMANENT MAGNETS SUITABLE FOR PRODUCTION AT THE INDUSTRIAL LEVEL.
IF THIS PROJECT IS SUCCESSFUL IT WILL HAVE A MAJOR IMPACT IN THE DESIGN OF ELECTRIC VEHICLES AND ELECTRICAL MACHINES IN EUROPE; IN PARTICULAR, FOR DUAL-MODE TROLLEY BUSES WHERE BRUSHLESS ELECTRIC MOTORS ARE TO BE INTEGRATED IN THE WHEELS; HIGH-SPEED REVERSIBLE BRUSHLESS ELECTRIC MACHINES FOR USE IN FLYWHEEL BUFFER UNITS AND IN AUXILIARY ELECTRIC DEVICES USED AS ACTIVATORS IN VEHICLE APPLICATIONS.
Fields of science (EuroSciVoc)
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
- engineering and technology mechanical engineering manufacturing engineering
- natural sciences chemical sciences inorganic chemistry noble gases
- natural sciences chemical sciences organic chemistry aldehydes
- social sciences social geography transport electric vehicles
- natural sciences chemical sciences polymer sciences
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Funding scheme (or “Type of Action”) inside a programme with common features. It specifies: the scope of what is funded; the reimbursement rate; specific evaluation criteria to qualify for funding; and the use of simplified forms of costs like lump sums.
Coordinator
20128 Milano
Italy
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.