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Title: Binder Jetting: A Novel NdFeB Bonded Magnet Fabrication Process

Journal Article · · JOM. Journal of the Minerals, Metals & Materials Society
 [1];  [2];  [1];  [3];  [1];  [4];  [4];  [5];  [6]
  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Univ. of Tennessee, Knoxville, TN (United States)
  3. Univ. of Tennessee, Knoxville, TN (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  4. Tru-Design, LLC, Knoxville, TN (United States)
  5. Magnet Applications, Inc., DuBoise, PA (United States)
  6. Magnet Applications, Inc., DuBoise, PA (United States)
+ Show Author Affiliations

Our goal of this research is to fabricate near-net-shape isotropic (Nd)2Fe14B-based (NdFeB) bonded magnets using a three dimensional printing process to compete with conventional injection molding techniques used for bonded magnets. Additive manufacturing minimizes the waste of critical materials and allows for the creation of complex shapes and sizes. The binder jetting process works similarly to an inkjet printer. A print-head passes over a bed of NdFeB powder and deposits a polymer binding agent to bind the layer of particles together. The bound powder is then coated with another layer of powder, building the desired shape in successive layers of bonded powder. Upon completion, the green part and surrounding powders are placed in an oven at temperatures between 100°C and 150°C for 4–6 h to cure the binder. After curing, the excess powder can be brushed away to reveal the completed “green” part. Green magnet parts were then infiltrated with a clear urethane resin to achieve the measured density of the magnet of 3.47 g/cm3 close to 46% relative to the NdFeB single crystal density of 7.6 g/cm3. Magnetic measurements indicate that there is no degradation in the magnetic properties. In conclusion, this study provides a new pathway for preparing near-net-shape bonded magnets for various magnetic applications.

Research Organization:
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Critical Materials Institute (CMI)
Sponsoring Organization:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
Grant/Contract Number:
AC05-00OR22725
OSTI ID:
1260082
Journal Information:
JOM. Journal of the Minerals, Metals & Materials Society, Vol. 68, Issue 7; ISSN 1047-4838
Publisher:
SpringerCopyright Statement
Country of Publication:
United States
Language:
English
Citation Metrics:
Cited by: 97 works
Citation information provided by
Web of Science

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Cited By (14)

Big Area Additive Manufacturing of High Performance Bonded NdFeB Magnets journal October 2016
Net Shape 3D Printed NdFeB Permanent Magnet : Net Shape 3D Printed NdFeB Permanent Magnet journal April 2017
A ReaxFF molecular dynamics study of molecular-level interactions during binder jetting 3D-printing journal January 2019
A comprehensive review of recent developments in 3D printing technique for ceramic membrane fabrication for water purification journal January 2019
Powder-bed additive manufacturing for aerospace application: Techniques, metallic and metal/ceramic composite materials and trends journal January 2019
Topology optimized and 3D printed polymer-bonded permanent magnets for a predefined external field journal August 2017
3D Printing of Functional Assemblies with Integrated Polymer-Bonded Magnets Demonstrated with a Prototype of a Rotary Blood Pump journal August 2018
Processing of Alnico Magnets by Additive Manufacturing journal November 2019
Influence of Melt-Pool Stability in 3D Printing of NdFeB Magnets on Density and Magnetic Properties journal December 2019
A review on recent developments in binder jetting metal additive manufacturing: materials and process characteristics journal September 2019
Hybrid Materials for Functional 3D Printing journal October 2018
3D printing of functional assemblies with integrated polymer-bonded magnets demonstrated with a prototype of a rotary blood pump text January 2018
3D Printing of Functional Assemblies with Integrated Polymer-Bonded Magnets Demonstrated with a Prototype of a Rotary Blood Pump text January 2018
Topology Optimized and 3D Printed Polymer Bonded Permanent Magnets for a Predefined External Field text January 2017

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