Net Shape 3D Printed NdFeB Permanent Magnet

Abstract

Three dimensional printing enables realization of complex shape rare earth permanent magnet that enable unlocking the full potential of electrical devices for energy consumption and renewable energy production.

Additive Manufactured Polymer-Bonded Isotropic NdFeB Magnets by Stereolithography and Their Comparison to Fused Filament Fabricated and Selective Laser Sintered Magnets

“…The PBF process can be divided into the heating source. Following commonly used PBF printing techniques are used to investigate the capability to print hard or soft magnets: electron beam melting (EBM) [15], selective laser melting (SLM) [16,17,18,19,20,21], and selective laser sintering (SLS). SLS does not completely melt each powder layer but sinter the particles to retain their original microstructure.…”

Refining the Microstructure of Fe‐Nd‐B by Selective Laser Melting

“…It shows a mean powder size distribution of about 40 μm. The flow rate of 3.33 g s −1 is comparable to other powders typically used for 3D printing . Its chemical composition has significantly less amount of rare earth metals (MQP‐S ≈8 at%) compared to powder usually used for the production of conventional sintered magnets (≈14–18 at%).…”

“…The high heating and cooling rates of the laser make the solidification sequence difficult to control . Recently, it has been demonstrated that fine‐tuning the laser parameters may result in stabilization of the intended Fe 14 Nd 2 B phase with reduced (but still present) iron segregation for high cooling rates and the MQP‐S powder used . In general, microstructure and related properties of 3D printed (SLM) components are mainly influenced by processing parameters (laser power, laser scan velocity, laser scan grid space, substrate conditions, thickness of powder layer) and powder characteristics (particle shape, rheology, particle size, inner porosity, purity, humidity) …”

“…[4] There are only a few studies focusing on fabrication of MQ powder by laser melting and electron beam melting. [5][6][7] Commercially available MQP-S powder is an atomized spherical nanocrystalline powder supplied by Magnequench Corporation. It shows a mean powder size distribution of about 40 μm.…”

“…The flow rate of 3.33 g s À1 is comparable to other powders typically used for 3D printing. [5] Its chemical composition has significantly less amount of rare earth metals (MQP-S %8 at %) compared to powder usually used for the production of conventional sintered magnets (%14-18 at%). The coarse and lean rare earth powder results in less ignitability and is therefore easier to handle.…”