Amorphous-crystalline nanostructured Nd-Fe-B permanent magnets using laser powder bed fusion: Metallurgy and magnetic properties

Wu, Julan; Aboulkhair, Nesma T.; Robertson, Stuart; Zhou, Zhaoxia; Bagot, P.A.J.; Moody, Michael P.; Ashcroft, Ian; Hague, Richard

doi:10.1016/j.actamat.2023.119239

Cited by 10 publications

(7 citation statements)

References 55 publications

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“…This was achieved using a relatively low energy input during PBF-LB processing, which leads to extremely rapid cooling and hence a fine, equiaxed microstructure without dendrite growth or excessive α-Fe. Wu et al showed that remelting Nd-Fe-B during PBF-LB led to the transformation of the coarse grains of the previously solidified layer to fine ones, favorable for the permanent magnetic properties [203]. Alignment of the magnetic particles in this type of AM is still a problematic task.…”

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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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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“…Bittner F et al [49] used the SLM technology to prepare a Nd-Fe-B magnet with H c of 921 kA/m, B r of 0.63 T, and (BH) max of 63 kJ/m 3 without further additions of Nd-rich, low-melting-point alloys or other post-treatments. Julan Wu et al [55] presented an in-depth analysis of the AM magnet's grain structure for the first time in terms of morphology, size distribution, and texture. They investigated the formation and transformation mechanisms of complex phases and the development of nanocrystalline microstructures during the SLM process and found that remelting during processing leads to the transformation of coarse grains in the solidified layer into fine grains, which is shown in Figure 2b, and it is favorable for the improvement of magnet properties.…”

Section: Laser Powder Bed Fusion (Lpbf) Nd-fe-b Magnetsmentioning

confidence: 99%

“…But for full-density AM magnets, improving H c is the key to further development. [29,34,43,47,49,55,56,58,[60][61][62]64,66,67].…”

Section: Binder Jetting (Bj) Nd-fe-b Magnetsmentioning

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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“…Therefore, before they find commercial applications, they must be subjected to modification to increase their resistance to external environmental factors. The search for solutions to increase this level of protection using different magnet coatings has been performed in many studies [ 3 , 4 , 8 , 9 , 10 ]. Among the most commonly used coatings are Ni-Cu-Ni, Zn, Rubber, Au, PTFE, Cr, and Ti Nitride [ 5 , 6 , 7 , 8 , 9 , 10 ].…”

Section: Introductionmentioning

confidence: 99%

“…The search for solutions to increase this level of protection using different magnet coatings has been performed in many studies [ 3 , 4 , 8 , 9 , 10 ]. Among the most commonly used coatings are Ni-Cu-Ni, Zn, Rubber, Au, PTFE, Cr, and Ti Nitride [ 5 , 6 , 7 , 8 , 9 , 10 ]. Coating manufacturing methods include the best-known example, based on electrochemical processes [ 8 ], or otherwise surface polishing by industrial robots and cold-sprayed coatings used for smaller scale [ 7 , 11 , 12 , 13 , 14 , 15 ].…”

Section: Introductionmentioning

confidence: 99%

Commercial-Scale Modification of NdFeB Magnets under Laser-Assisted Conditions

Radwan-Pragłowska,

Łysiak

et al. 2024

Nanomaterials

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Rare Earth elements (REE) such as NdFeB are commonly used to produce permanent magnets. Thanks to their superior properties, these materials are highly desirable for green energy applications such as wind power generators or electric cars. Currently, REEs are critical for the ongoing development of eco-friendly solutions in different industrial branches. The emerging issue of REE depletion has led to a need for new methods to enable the life cycle elongation, resistance to wear, and external factors improvement of NdFeB magnets. This can be achieved by advanced, nanostructured coating formation of magnet surfaces to increase their functionality and protect from humidity, pressure, temperature, and other factors. The aim of the following research was to develop a new, scalable strategy for the modification of NdFeB magnets using laser-assisted technique, also known as Laser cladding. For this purpose, four different micropowders were used to modify commercial NdFeB samples. The products were investigated for their morphology, structure, chemical composition, and crystallography. Moreover, magnetic flux density was evaluated. Our results showed that laser cladding constitutes a promising strategy for REE-based permanent magnets modification and regeneration and may help to improve durability and resistance of NdFeB components.

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Amorphous-crystalline nanostructured Nd-Fe-B permanent magnets using laser powder bed fusion: Metallurgy and magnetic properties

Cited by 10 publications

References 55 publications

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

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

Commercial-Scale Modification of NdFeB Magnets under Laser-Assisted Conditions

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