Low-Field Alignment of Anisotropic Bonded Magnets for Additive Manufacturing of Permanent Magnet Motors

Khazdozian, Helena; Li, Ling; Paranthaman, M.; McCall, S.; Kramer, M. J.; Nlebedim, Ikenna C.

doi:10.1007/s11837-018-3242-0

Cited by 14 publications

(4 citation statements)

References 24 publications

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“…The authors' results predicted higher degree of alignment (based on remanence (Mr)-to-saturation magnetization (Ms) ratio) at lower field strength for magnets aligned at higher temperature (above the melting point of EVA). These results were further validated by Khazdozian et al [21], suggesting that alignment field, 0H < 1T, is sufficient to align 65 vol.% of Nd-Fe-B magnet particles (Dy-free anisotropic Magfine-MF18P) bonded in Nylon12 to the applied field direction.…”

Section: Introductionsupporting

confidence: 64%

Functionalizing magnet additive manufacturing with in-situ magnetic field source

Sarkar

Somashekara

Paranthaman

et al. 2020

Additive Manufacturing

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Additive manufacturing via 3-D printing technologies have become a frontier in materials research, including its application in the development and recycling of permanent magnets. This work addresses the opportunity to integrate magnetic field sources into 3-D printing process in order to enable printing, alignment of anisotropic permanent magnets or magnetizing of magnetic filler materials, without requiring further processing. A non-axisymmetric electromagnet-type field source architecture was designed, modelled, constructed, and installed to a fused filament commercial 3-D printer and tested. The testing was performed by applying magnetic field while printing composite anisotropic Nd-Fe-B+Sm-Fe-N powders bonded in Nylon12 (65vol.%) and recycled Sm-Co powder bonded in PLA (15vol.%). Magnetic characterization indicated that the degree-of-alignment of the magnet powders increased both with alignment field strength (controlled by the current applied to the magnetizing system) and the printing temperature. Both coercivity and remanence were found to be strongly dependent on the degree-of-alignment except for printing performed below but near the Curie temperature of Nd-Fe-B (310°C). Under applied field of 0.15 kOe, Sm-Co and hybrid Nd-Fe-B/Sm-Fe-N printed samples showed degrees-of-alignment of 83% and 65%, respectively. The variations in coercivity were consistent with previous observations in bonded magnet materials. This work verifies that integration of magnetic field sources into 3-D printing processes will result in magnetic alignment of particles while ensuring that other advantages of 3-D printing are retained.

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Section: Introductionsupporting

confidence: 64%

Functionalizing magnet additive manufacturing with in-situ magnetic field source

Sarkar

Somashekara

Paranthaman

et al. 2020

Additive Manufacturing

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“…They concluded that a magnetic field of <1000 mT could overcome the viscosity of the polymer, once it was heated past its melting point, allowing all particles to be aligned along their easy axis. A later study by the same group conducted the same experiment using anisotropic NdFeB powder mixed with polyamide-12 (Khazdozian et al, 2018). They found a majority (87%) of crystals aligned with a field of just 250 mT with very little increase in alignment between 500 and 3000 mT.…”

Section: Introductionmentioning

confidence: 93%

Selective laser sintering of bonded anisotropic permanent magnets using an in situ alignment fixture

Mapley

Tansley

Pauls

et al. 2021

RPJ

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Purpose Additive manufacturing (AM) techniques have been developed to rapidly produce custom designs from a multitude of materials. Bonded permanent magnets (PMs) have been produced via several AM techniques to allow for rapid manufacture of complex geometries. These magnets, however, tend to suffer from lower residual induction than the industry standard of injection moulding primarily due to the lower packing density of the magnetic particles and secondly due to the feedstock consisting of neodymium-iron-boron (Nd-Fe-B) powder with isotropic magnetic properties. As there is no compaction during most AM processes, increasing the packing density is very difficult and therefore the purpose of this study was to increase the magnetic properties of the PMs without increasing the part density. Design/methodology/approach Accordingly, this research investigates the use of anisotropic NdFeB feedstock coupled with an in-situ alignment fixture into an AM process known as selective laser sintering (SLS) to increase the magnetic properties of AM magnets. A Helmholtz coil array was added to an SLS machine and used to expose each powder layer during part fabrication to a near-uniform magnetic field of 20.4 mT prior to consolidation by the laser. Findings Permeagraph measurements of the parts showed that the alignment field introduced residual induction anisotropy of up to 46.4 ± 2.2% when measured in directions parallel and perpendicular to the alignment field. X-ray diffraction measurements also demonstrated a convergence of the orientation of the crystals when the magnets were processed in the presence of the alignment field. Originality/value A novel active alignment fixture for SLS was introduced and was experimentally shown to induce anisotropy in bonded PMs. Thus demonstrating a new method for the enhancement in energy density of PMs produced via AM methods.

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“…4(f). Aligned anisotropic structures were obtained by applying an external magnetic field, indicating great potential in addressing rare earth elements criticality [135].…”

Section: Magnetic-assisted 3d Printingmentioning

confidence: 99%

Advances in 3D printing of magnetic materials: Fabrication, properties, and their applications

et al. 2022

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Magnetic materials are of increasing importance for many essential applications due to their unique magnetic properties. However, due to the limited fabrication ability, magnetic materials are restricted by simple geometric shapes. Three-dimensional (3D) printing is a highly versatile technique that can be utilized for constructing magnetic materials. The shape flexibility of magnets unleashes opportunities for magnetic composites with reducing post-manufacturing costs, motivating the review on 3D printing of magnetic materials. This paper focuses on recent achievements of magnetic materials using 3D printing technologies, followed by the characterization of their magnetic properties, which are further enhanced by modification. Interestingly, the corresponding properties depend on the intrinsic nature of starting materials, 3D printing processing parameters, and the optimized structural design. More emphasis is placed on the functional applications of 3D-printed magnetic materials in different fields. Lastly, the current challenges and future opportunities are also addressed.

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Low-Field Alignment of Anisotropic Bonded Magnets for Additive Manufacturing of Permanent Magnet Motors

Cited by 14 publications

References 24 publications

Functionalizing magnet additive manufacturing with in-situ magnetic field source

Functionalizing magnet additive manufacturing with in-situ magnetic field source

Selective laser sintering of bonded anisotropic permanent magnets using an in situ alignment fixture

Advances in 3D printing of magnetic materials: Fabrication, properties, and their applications

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