Current challenges in NdFeB permanent magnets manufacturing by Powder Injection Molding (PIM): A review

Crozier-Bioud, Thomas; Momeni, Vahid; González-Gutiérrez, Joamín; Kukla, Christian; Luca, Sorana; Rolère, Sébastien

doi:10.1016/j.mtphys.2023.101082

Cited by 8 publications

(5 citation statements)

References 87 publications

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“…[54,57] One reason for these relatively low magnetic performances could be the high level of impurities (C, O, and N) which are known to be detrimental to the magnetic properties. [21,72,73] No clear difference on the contamination levels was evidenced between the 5 and 3.5 μm batches. We are not in a position to propose an explanation for these a priori surprising results.…”

Section: Discussionmentioning

confidence: 87%

Toward the Improvement of the Short‐Loop Recycling of Dy‐Rich Nd–Fe–B Permanent Magnets: Experimental and Numerical Approaches

Bacchetta,

Luca,

Rado

et al. 2024

Adv Eng Mater

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The method of short‐loop recycling of Nd‐Fe‐B magnets is implemented, with End of Life (EoL) magnets used as a source of Heavy Rare Earths (HRE). Partially recycled magnets are fabricated by co‐sintering of HRE‐free powders obtained from strip casted alloys, blended with HRE‐rich powders obtained from EoL magnets. The impact of several process parameters (blending ratio, sintering cycle and HRE‐rich recycled particle sizes) on the microstructure and magnetic properties are discussed. A coercivity gain up to 160 kA m‐1 per wt. % of Dy with respect to the HRE‐free magnets is reported, even though impurities are incorporated. Microstructural characterizations show a heterogeneous Dy localization in core‐shell/anti‐core‐shell structures, and thus a non‐optimal use of HRE. The experimental results are compared with finite elements simulations performed using existing data of bulk Dy diffusion coefficients. The simulation model consists of a network of square grains separated by a liquid phase, whose fraction is based on the ternary Nd‐Fe‐B phase diagram. Results show similarities with the observed microstructures, and point to the interest of reducing the Dy‐rich particle size with respect to the main powder. This study provides new insights into the Dy transport mechanisms at stake in an efficient short‐loop recycling of HRE.This article is protected by copyright. All rights reserved.

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Section: Discussionmentioning

confidence: 87%

Toward the Improvement of the Short‐Loop Recycling of Dy‐Rich Nd–Fe–B Permanent Magnets: Experimental and Numerical Approaches

Bacchetta,

Luca,

Rado

et al. 2024

Adv Eng Mater

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“…Also, RE-rich alloys will better tolerate organic contamination. Metal Injection Molding of NdFeB magnets still presents numerous technical challenges but already produces magnetic parts with useful properties, which gives it a realistic processing route for permanent magnets [194]. One of the main issues is the orientation of the printed magnetic particles.…”

Section: Net-shape Manufacturingmentioning

confidence: 99%

The Future of Permanent-Magnet-Based Electric Motors: How Will Rare Earths Affect Electrification?

Podmiljšak,

Saje,

Jenuš

et al. 2024

Materials

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In this review article, we focus on the relationship between permanent magnets and the electric motor, as this relationship has not been covered in a review paper before. With the increasing focus on battery research, other parts of the electric system have been neglected. To make electrification a smooth transition, as has been promised by governing bodies, we need to understand and improve the electric motor and its main component, the magnet. Today’s review papers cover only the engineering perspective of the electric motor or the material-science perspective of the magnetic material, but not both together, which is a crucial part of understanding the needs of electric-motor design and the possibilities that a magnet can give them. We review the road that leads to today’s state-of-the-art in electric motors and magnet design and give possible future roads to tackle the obstacles ahead and reach the goals of a fully electric transportation system. With new technologies now available, like additive manufacturing and artificial intelligence, electric motor designers have not yet exploited the possibilities the new freedom of design brings. New out-of-the-box designs will have to emerge to realize the full potential of the new technology. We also focus on the rare-earth crisis and how future price fluctuations can be avoided. Recycling plays a huge role in this, and developing a self-sustained circular economy will be critical, but the road to it is still very steep, as ongoing projects show.

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“…A proof of concept for additive manufacturing of (Sm, Zr)Fe 11 Ti permanent magnets was presented by Neznakhin et al [72]. The permanent magnets were prepared by a selective laser melting method using (Sm, Zr)Fe 11 Ti powder and its mixtures with a low-melting-point additive Sm 75 (Cu, Co) 25 . The additive facilitates liquid-phase sintering of the main alloy particles without causing drastic changes in the microstructure of the alloy.…”

Section: Additive Manufacturing Of Sm(fe T) 12 Rare Earth Permanent M...mentioning

confidence: 99%

“…At the same time, the poor mechanical properties of Nd-Fe-B magnets prepared by traditional technologies limit the design of the manufacturing process of magnets, making it difficult to realize complex design solutions. There are four main traditional preparation technologies for Nd-Fe-B magnets: sintering, bonding, hot-pressing, and thermal deformation [24][25][26]. Although the traditional sintering technology can obtain magnets with better magnetic properties, the magnets prepared by the sintering process generally have poor mechanical properties and cannot form magnets with complex structures.…”

Section: Introductionmentioning

confidence: 99%

Additive Manufacturing of Rare Earth Permanent Magnetic Materials: Research Status and Prospects

Chen,

Xiong,

2024

Metals

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With the rapid development of intelligent manufacturing, modern components are accelerating toward being light weight, miniaturized, and complex, which provides a broad space for the application of rare earth permanent magnet materials. As an emerging near-net-shape manufacturing process, additive manufacturing (AM) has a short process flow and significantly reduces material loss and energy consumption, which brings new possibilities and impetus to the development of rare earth permanent magnetic materials. Here, the applications of AM technology in the field of rare earth permanent magnets in recent years are reviewed and prospected, including laser powder bed fusion (LPBF), fused deposition modeling (FDM), and binder jetting (BJ) techniques. Research has found that the magnetic properties of AM Nd-Fe-B magnets can reach or even exceed the traditional bonded magnets. In addition, in situ magnetic field alignment, in situ grain boundary infiltration, and post-processing methods are effective in enhancing the magnetic properties of AM magnets. These results have laid a good foundation for the development of AM rare earth permanent magnets.

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Current challenges in NdFeB permanent magnets manufacturing by Powder Injection Molding (PIM): A review

Cited by 8 publications

References 87 publications

Toward the Improvement of the Short‐Loop Recycling of Dy‐Rich Nd–Fe–B Permanent Magnets: Experimental and Numerical Approaches

Toward the Improvement of the Short‐Loop Recycling of Dy‐Rich Nd–Fe–B Permanent Magnets: Experimental and Numerical Approaches

The Future of Permanent-Magnet-Based Electric Motors: How Will Rare Earths Affect Electrification?

Additive Manufacturing of Rare Earth Permanent Magnetic Materials: Research Status and Prospects

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