Production and Application of HPMS Recycled Bonded Permanent Magnets for a Traction Motor Application

Kimiabeigi, Mohammad; Sheridan, Richard; Widmer, James D.; Walton, Allan; Farr, M.; Scholes, Ben; Harris, I.R.

doi:10.1109/tie.2017.2762625

Cited by 30 publications

(19 citation statements)

References 33 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Nanocrystalline Nd-Fe-B alloys cannot be conventionally sintered which eludes their high coercivity exploitation because the ultrafine grain structure will undergo excessive grain coarsening at elevated sintering temperatures, resulting into coercivity losses. Due to this reason, either the bonded magnets are their primary application [5] or the rapid processing methodologies are applied, e.g., spark plasma sintering, hot deformation, and die-upsetting [1,6,7]. Previously we have demonstrated the control in SPS parameters resulted in high coercivity (H Ci ≈ 1200 kA/m) of the recycled HDDR Nd-Fe-B-type isotropic magnets [7] and that the particle size has a critical significance on the sinterability and oxygen uptake of the recycled powder [8].…”

Section: Introductionmentioning

confidence: 99%

Spark Plasma Sintering as an Effective Texturing Tool for Reprocessing Recycled HDDR Nd-Fe-B Magnets with Lossless Coercivity

Ikram

Awais

Sheridan

et al. 2020

Metals

Self Cite

View full text Add to dashboard Cite

The low-pressure hot-deformation methodology was applied to reprocess the nanocrystalline hydrogenation–disproportionation–desorption–recombination (HDDR) Nd-Fe-B powders from end-of-life (EOL) permanent magnets’ waste to determine the mechanism of texture development and the resultant improvement in remanence (and BHmax) in the recycled material. Both the hot-pressed and hot-deformed magnets produced via spark plasma sintering (SPS) were compared in terms of their magnetic properties with respect to forging pressures. Also, a comparison was established with the microstructure to cite the effectiveness of texture development at low deformation rates and pressures which is pivotal for retaining high coercivity. The hot-pressed magnets maintain the high coercivity (better than 100%) of the original recycled powder due to the control of SPS conditions. The hot deformation pressure was varied from 100–150 MPa at 750 °C processing temperature to identify the optimal texture development in the sintered HDDR Nd-Fe-B magnets. The effect of post-hot-deformation thermal treatment was also investigated, which helped in boosting the overall magnetic properties and better than the recycled feedstock. This low-pressure hot deformation process improved the remanence of the hot-pressed magnet by 11% over the starting recycled powder. The Mr/MS ratio which was 0.5 for the hot-pressed magnets increased to 0.64 for the magnets hot-deformed at 150 MPa. Also, a 55% reduction in height of the sample was achieved with the c-axis texture, indicating approximately 23% higher remanence over the isotropic hot-pressed magnets. After hot deformation, the intrinsic coercivity (HCi) of 960 kA/m and the remanence (Br) value of 1.01 T at 150 MPa is indicative that the controlled SPS reprocessing technique can prevent microstructure related losses in the magnetic properties of the recycled materials. This route also suggests that the scrap Nd-Fe-B magnets can be treated with recoverable magnetic properties subsequently via HDDR technique and controlled hot deformation with a follow-up annealing.

show abstract

Section: Introductionmentioning

confidence: 99%

Spark Plasma Sintering as an Effective Texturing Tool for Reprocessing Recycled HDDR Nd-Fe-B Magnets with Lossless Coercivity

Ikram

Awais

Sheridan

et al. 2020

Metals

Self Cite

View full text Add to dashboard Cite

show abstract

“…In [10], the use of recycled PMs in electrical machines have been studied on an Interior Permanent Magnet Machine (IPM) with bonded NdFeB PMs. In such study, PM material recycled with the hydrogen processing of magnetic scrap is used for the design and prototyping of an IPM motor.…”

Section: Introductionmentioning

confidence: 99%

Design and Experimental Investigation of a Hybrid Rotor Permanent Magnet Modular Machine with 3D Flux Paths Accounting for Recyclability of Permanent Magnet Material

et al. 2020

View full text Add to dashboard Cite

Rare-earth metals used for manufacturing Permanent Magnets (PMs) remain classified as critical raw materials by the European Commission. In order to secure the supply of electrical machines due to the increasing demand of Hybrid and Full Electrical Vehicles ((H)EVs), recycling has emerged as a valuable alternative. Hence, this paper presents the concept of a modular PM machine with a hybrid rotor and 3D flux paths, for application in ((H)EVs). The proposed machine topology is intended to facilitate the extraction of PM material towards a recycling process. The selection of a machine for prototyping is carried out by investigating the effect of the variation of the number of rotor teeth and stator modules on various parameters, with models developed in Finite Element (FE). Finally, the models developed of the selected combination were validated with a detailed experimental evaluation of the prototype.

show abstract

“…These novel materials are not likely to outperform the Nd-Fe-B and Samarium-Cobalt (Sm-Co) PM materials but could provide a cost efficient rare-earth metal free alternative. In addition, research is performed on recycled rare-earth magnets, expected to have properties in between ferrites and commercial Nd-Fe-B [12]. It can be of interest to investigate how to best utilise possible new or recycled materials, even though the novel magnets are not developed and commercialised yet.…”

Section: Introductionmentioning

confidence: 99%

The Influence of Permanent Magnet Material Properties on Generator Rotor Design

Eklund

Eriksson

2019

Energies

View full text Add to dashboard Cite

Due to the price and supply insecurities for rare earth metal-based permanent magnet (PM) materials, a search for new PM materials is ongoing. The properties of a new PM material are not known yet, but a span of likely parameters can be studied. This paper presents an investigation on how the remanence and recoil permeability of a PM material affect its usefulness in a low speed, multi-pole, and PM synchronous generator. Demagnetisation is also considered. The investigation is carried out by constrained optimisation of three different rotor topologies for maximum torque production for different PM material parameters and a fixed PM maximum energy. The rotor topologies used are surface mounted PM rotor, spoke type PM rotor and an interior PM rotor with radially magnetised PMs. The three different rotor topologies have their best performance for different kinds of materials. The spoke type PM rotor is the best at utilising low remanence materials as long as they are sufficiently resistant to demagnetisation. The surface mounted PM rotor works best with very demagnetisation resistant PM materials with a high remanence, while the radial interior PM rotor is preferable for high remanence materials with low demagnetisation resistance.interact with the demagnetisation magnetic flux density curve. Different rotor topologies have been studied previously. In [13], three topologies, similar to those studied here, are compared for use in 4-pole traction motors for trains. Similar topologies are compared for use as an aircraft starter-generator in [14]. Five different topologies, not including the spoke-type rotor, are compared in [15]. Ref. [16] also compares five different topologies, including the spoke-type rotor. Ref.[17] compares machines with Nd-Fe-B, Sm-Co and alnico for surface mounted 4-pole machines. Ref.[18] compares three machine configurations for interior v-shaped magnets for two different materials: the novel material NdFe 12 N x and a conventional Nd-Fe-B magnet. A spoke-type rotor with ferrites is compared to a rotor with surface mounted Nd-Fe-B magnets for a wind power generator in [19,20]. A comparison of demagnetization risk for the same generator types is presented in [21].The aim of this paper is to study how the magnetic properties of PM materials affect the machine design in low-speed radial flux PM generators. To our knowledge, there has not been any previous study combining material properties with rotor design and rotor topology choice. The results from this study could give hints on which property to improve when developing new PM materials as well as on the suitability of a material with certain magnetic properties for different generator topologies.

show abstract

Production and Application of HPMS Recycled Bonded Permanent Magnets for a Traction Motor Application

Cited by 30 publications

References 33 publications

Spark Plasma Sintering as an Effective Texturing Tool for Reprocessing Recycled HDDR Nd-Fe-B Magnets with Lossless Coercivity

Spark Plasma Sintering as an Effective Texturing Tool for Reprocessing Recycled HDDR Nd-Fe-B Magnets with Lossless Coercivity

Design and Experimental Investigation of a Hybrid Rotor Permanent Magnet Modular Machine with 3D Flux Paths Accounting for Recyclability of Permanent Magnet Material

The Influence of Permanent Magnet Material Properties on Generator Rotor Design

Contact Info

Product

Resources

About