High-coercivity copper-rich Nd-Fe-B magnets by powder bed fusion using laser beam method

Tosoni, Olivier; Mendonça, Elisa Borges; Reijonen, Joni; Antikainen, Atte; Schäfer, Lukas; Riegg, Stefan; Gutfleisch, Oliver

doi:10.1016/j.addma.2023.103426

Cited by 10 publications

(9 citation statements)

References 40 publications

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“…Goll et al [201] reached properties of H CJ = 925 kA/m, Br = 0.58 T, and (BH) max = 62.3 kJ/m 3 with this technique. Tosoni et al [202] used a copper-rich Nd-Fe-B composition synthesized close to industrial standards to reach even higher coercivities up to H CJ = 1790 kA/m. 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.…”

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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“…We selected Nd-Fe-B-based permanent magnet powder as model material, as i) its spectral lines are within the measurement range of our OES system and at least for high temperatures clearly differentiable [12] and ii) permanent magnet AM by laser powder bed fusion, is an emerging application, with many material-related issues and sometimes narrow processing windows that need to be better understood. [13]…”

Section: Introductionmentioning

confidence: 99%

In-situ monitoring of the material composition in PBF-LB via optical emission spectroscopy

Ziefuß

Streubel

Gabriel

et al. 2023

Preprint

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Powder bed fusion using a laser beam of metals (PBF-LB/M) is a widely used additive manufacturing (AM) technique that enables the material-efficient fabrication of complex geometries in metallic parts. However, achieving high-quality parts with desired properties heavily depends on variances in the manufacturing process and powder composition, making quality control an indispensable aspect of almost all applications. Today, mainly grayscale imaging or pyrometry are employed, whereas in situ recording of chemical (compositional) information has rarely been done during LBF-LB/M. This pilot study explores the feasibility of in-situ optical emission spectroscopy (OES) for elemental analysis of metallic samples during PBF-LB, at the example of Nd-Fe-B. Our findings suggest that the local emissivity of Fe and Nd lines can serve as a reliable indicator to determine the temperature and elemental concentration in the plasma. The results showed that Online-OES during PBF-LB enables tracking of how Nd content in as-build parts critically depends on the laser parameter used while printing the part.

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“…[5,10] In AlSi10Mg alloys, the fast cooling rates result in an ultrafine supersaturated Si-rich network inside each grain which positively influences the corrosion behavior; however, high residual stresses and microstructural inhomogeneity negatively affect further mechanical properties like ductility and fatigue resistance. [7,11,12] Yet, compared with structural materials (e.g., 316L, AlSi10Mg, and Ti6Al4V), functional materials such as magnetic shape memory alloys (e.g., Ni-Mn-In or Co-Ni-Ga [13] ), magnetocaloric materials, or rare-earth permanent magnets (e.g., Nd-Fe-B [14,15] ) are rarely produced with PBF-LB/M; thus, further research is necessary to correlate the melting-induced microstructures with the functional read-out in as-built parts. [13,16,17] The desirable microstructure for high coercivity in, e.g., Nd-Fe-B alloys consists of submicrometer-or micrometer-sized Nd 2 Fe 14 B grains isolated by a paramagnetic grain boundary phase.…”

Section: Introductionmentioning

confidence: 99%

Influence of Colloidal Additivation with Surfactant‐Free Laser‐Generated Metal Nanoparticles on the Microstructure of Suction‐Cast Nd–Fe–B Alloy

Liu,

Yang,

Staab

et al. 2023

Adv Eng Mater

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Development of new powder feedstocks using nanoparticles (NPs) has the potential to influence the microstructure of as‐built parts and overcome the limitations of current powder‐based additive manufacturing (AM) techniques. The focus of this study is to investigate the impact of NP‐modified magnetic microparticle powder feedstock on the microstructure of suction‐cast Nd‐Fe‐B‐based alloys. This particular casting method has been recognized for its ability to replicate, to some extent, the melting and rapid solidification stages inherent to metal powder‐based AM techniques such as Powder Bed Fusion using a Laser Beam (PBF‐LB). Two types of NP materials, Ag and ZrB2, are used, and their effects on the grain size distribution and dendritic structures are evaluated after suction casting. Ag NPs result in smaller, more uniform grain sizes. ZrB2 NPs result in uniformly distributed grain sizes at much lower mass loadings. The results show that feedstock powder surface modification with low‐melting‐point metal NPs can improve permanent magnets’ microstructure and magnetic properties, at below 1 vol.%, equal to sub‐monolayer surface loads. This study highlights the potential of using NPs to develop new powder feedstocks for AM, significantly improving the final part’s properties.This article is protected by copyright. All rights reserved.

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High-coercivity copper-rich Nd-Fe-B magnets by powder bed fusion using laser beam method

Cited by 10 publications

References 40 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?

In-situ monitoring of the material composition in PBF-LB via optical emission spectroscopy

Influence of Colloidal Additivation with Surfactant‐Free Laser‐Generated Metal Nanoparticles on the Microstructure of Suction‐Cast Nd–Fe–B Alloy

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