Advanced directional solidification methods have been used to produce large (>15 cm length) castings of Alnico permanent magnets with highly oriented columnar microstructures. In combination with subsequent thermomagnetic and draw thermal treatment, this method was used to enable the high coercivity, high-Titanium Alnico composition of 39% Co, 29.5% Fe, 14% Ni, 7.5% Ti, 7% Al, 3% Cu (weight %) to have an intrinsic coercivity (H ci) of 2.0 kOe, a remanence (B r) of 10.2 kG, and an energy product (BH) max of 10.9 MGOe. These properties compare favorably to typical properties for the commercial Alnico 9. Directional solidification of higher Ti compositions yielded anisotropic columnar grained microstructures if high heat extraction rates through the mold surface of at least 200 kW/m 2 were attained. This was achieved through the use of a thin walled (5 mm thick) high thermal conductivity SiC shell mold extracted from a molten Sn bath at a withdrawal rate of at least 200 mm/hour. However, higher Ti compositions did not result in further increases in magnet performance. Images of the microstructures collected by scanning electron microscopy (SEM) reveal a majority α phase with inclusions of secondary α γ phase. Transmission electron microscopy (TEM) reveals that the α phase has a spinodally decomposed microstructure of FeCo-rich needles in a NiAl-rich matrix. In the 7.5% Ti composition the diameter distribution of the FeCo needles was bimodal
The attraction between unequally sized like magnetic poles is characterized herein. Finite element analysis (FEA) simulation has verified that attraction can occur between like poles. Between two unequally sized like poles with various dimensions and alignments, a turning point (TP) appears on the curves of force vs. distance between them, which is caused by the localized demagnetization (LD). The LD plays a role far before the distance between the poles reduces to the TP. The LD area may have a changed polarity, making the attraction possible and not in violation of basic laws of magnetism. Here, the LD levels have been determined using FEA simulation, and the factors affecting the LD have been explored, including the geometry, the linearity of the BH curve, and the alignment of the magnet pairs. Novel devices can be designed with attraction between the centers of such like poles and repulsion when off-center.
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