With the advent of high-flux density permanent magnets based on rare earth elements such as neodymium (Nd) in the 1980s, permanent magnet-based electric machines had a clear performance and cost advantage over induction machines when weight and size were factors such as in hybrid electric vehicles and wind turbines. However, the advantages of the permanent magnet-based electric machines may be overshadowed by supply constraints and high prices of their key constituents, rare earth elements, which have seen nearly a 10-fold increase in price in the last 5 years and the imposition of export limits by the major producing country, China, since 2010. We outline the challenges, prospects, and pitfalls for several potential alloys that could replace Nd-based permanent magnets with more abundant and less strategically important elements.

No abstract

Permanent magnets play a vital role in modern society as a component in a wide range of devices utilized by many industries and consumers. In 1995, the world production of permanent magnets was estimated to be valued at $3.6 billion and growing at an annual rate of 12%. Bonded permanent magnets are the fastest growing segment of this market. Bonded magnet technology enables a wide variety of magnetic powders to be combined with several polymer and binder systems to produce magnetic components utilizing several processing options. In this article, we review the development of bonded magnet technology. The major classes of magnetic powders, binder systems, and processing technologies are described. Recent developments in magnetic material grades, e.g., anisotropic NdFeB, rare earth lean NdFeB, SmFe(N,C) are outlined. The current status of processing and binder options aimed at increasing the upper application temperature limit of these materials is highlighted. Finally, the improvements and future opportunities for bonded magnets are discussed.

No abstract

No abstract