Packing bimodal magnetic particles to fabricate highly dense anisotropic rare earth bonded permanent magnets

Liu, Xubo; Gandha, Kinjal; Wang, Haobo; Mungale, Kaustubh; Vaidya, Uday; Nlebedim, Ikenna C.; Paranthaman, M.

doi:10.1039/d3ra02349d

Cited by 5 publications

(3 citation statements)

References 35 publications

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“…The optimized magnet designs presented in this work can be produced by FDM 3D printing. ORNL's BAAM 3D printer has shown that it is possible to produce these magnets 20,22 because it can handle very high magnet filler loading. However, other commercially available printers may not be equipped to process the high‐volume fraction material necessary for these magnets.…”

Section: Resultsmentioning

confidence: 99%

“…In terms of the BAAM process described in references, 20,22 the feedstock is obtained by first pelletizing the composite magnet powder (Sm‐Fe‐N and Nd‐Fe‐B suspended in polymer binder) and then extruded through a heated nozzle that precisely deposits each layer onto a build platform. Each layer thickness corresponds to the extruder's nozzle diameter.…”

Section: Resultsmentioning

confidence: 99%

“…These advantages include increasing magnet supply chain by allowing for recyclability and the absence of molds that can significantly lower the manufacturing costs when compared with injection‐molded magnets. More recently, 81‐vol%‐printed polymer‐bonded magnets were obtained from composite pellets made from a starting magnet powder–Magfine MF15P 19 –using the Big Area Additive Manufacturing system 20 and an iterative process that progressed from 70–75 vol%. MF15P are a series of heat‐resistant powders made from Nd‐Fe‐B+Sm‐Fe‐N+Nylon 12 that do not contain dysprosium and have an energy product of 38 MGOe.…”

Section: Introductionmentioning

confidence: 99%

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Advanced multimaterial shape optimization methods as applied to advanced manufacturing of wind turbine generators

Sethuraman,

Glaws,

Skinner

et al. 2024

Wind Energy

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Currently, many utility‐scale wind turbine generator original equipment manufacturers are dependent on imported rare earth permanent magnets, which are susceptible to market risks from cost instability. To lower the production costs of these generators and stay competitive in the market, several small wind manufacturers are pursuing continuous improvements to both generator design and manufacturing. However, traditional design and manufacturing methods have yielded marginal improvements in wind power performance. This work presents novel methods to redesign a baseline 15‐kW wind turbine generator with reduced rare‐earth permanent magnets by leveraging cutting‐edge three‐dimensional (3D) printed polymer‐bonded permanent magnets and steel. Symmetric, asymmetric, and multimaterial‐magnet parametrization methods are introduced for shape optimization. We extend the symmetric and asymmetric methods to the back iron in the stator to further investigate the impact and opportunities for performance improvements with lesser active materials. We employ a design‐of‐experiments approach with parametric computer‐aided design for shape generation and evaluate different designs by magneto‐thermal modeling and finite‐element analysis. We use adaptive sampling technique to identify better performing designs with lesser magnet mass, higher efficiency, and lower cogging torque when compared with the baseline generator. Asymmetric pole designs resulted in a magnet mass in the range of 4.77–5.37 kg, which was 27%–35% lighter than the baseline generator, suggesting that a new design freedom exists that can be enabled by advanced manufacturing, such as 3D printing. Shaping the back iron in the stator resulted in material savings in electrical steel of up to 14.62 kg, which was 20% lighter than the baseline stator. We conducted a structural analysis to evaluate an optimized asymmetric rotor design from the point of view of mechanical integrity and air‐gap stiffness. The magnetically optimal shape profile was shown as having a positive impact on the radial stiffness, and an optimal solution was discovered to reduce the structural mass by nearly 30 kg, which was 29% lighter than the baseline.

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Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Advanced multimaterial shape optimization methods as applied to advanced manufacturing of wind turbine generators

Sethuraman,

Glaws,

Skinner

et al. 2024

Wind Energy

View full text Add to dashboard Cite

show abstract

Recycling of additively printed anisotropic Nd-Fe-B bonded magnets

Liu,

Gandha,

Nlebedim

et al. 2024

Journal of Magnetism and Magnetic Materials

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The effect of powder shape on the magnetic anisotropy in NdFeB bonded magnets

Qu,

Wu,

Zhang

et al. 2024

AIP Advances

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The advent of NdFeB bonded magnets with freedom of shape design is effective in achieving motor size and weight reductions. In this paper, the NdFeB bonded magnets were produced through calendaring molding, and the effect of powder shape on degree of alignment (DOA) of NdFeB bonded magnets was investigated. The magnetic measurement results demonstrate that platelet-shaped anisotropic Master Quality Authenticated (MQA) powders exhibit a significantly higher DOA compared to sphere-shaped anisotropic HDDR powders. Microstructural analysis reveals the presence of an oriented structure induced by mechanical stress in MQA bonded magnets, resulting in magnetic anisotropy. This observation is consistent with the difference in X-ray diffraction (XRD) patterns between the cross-section and surface of MQA bonded magnets. Conversely, spherical HDDR particles display minimal orientation and maintain a random distribution, resulting in magnetic isotropy. The XRD pattern of the cross-section of HDDR bonded magnets closely resembles that of its surface. In summary, our findings highlight the superior potential of platelet-shaped anisotropic MQA powders for achieving enhancing magnetic properties during the calendaring molding process, in contrast to sphere-shaped anisotropic HDDR powders. This study provides valuable insights into the determinants of mechanical particle orientation during the fabrication of anisotropic NdFeB bonded magnets, with implications for the development of high-performance bonded magnets.

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Packing bimodal magnetic particles to fabricate highly dense anisotropic rare earth bonded permanent magnets

Abstract: Bimodal particles of NdFeB and SmFeB yielded high-density bonded magnets. The energy product of 20 MGOe with 81 vol% magnet loading was demonstrated.

Cited by 5 publications

References 35 publications

Advanced multimaterial shape optimization methods as applied to advanced manufacturing of wind turbine generators

Advanced multimaterial shape optimization methods as applied to advanced manufacturing of wind turbine generators

Recycling of additively printed anisotropic Nd-Fe-B bonded magnets

The effect of powder shape on the magnetic anisotropy in NdFeB bonded magnets

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