Big area additive manufacturing of high performance bonded NdFeB magnets

Li, Ling; Tirado, Angelica; Nlebedim, I. C.; Rios, Orlando; Post, Brian; Kunc, Vlastimil; Lowden, R. R.; Lara-Curzio, Edgar; Fredette, Robert; Ormerod, John; Lograsso, Thomas A.; Paranthaman, M. Parans

doi:10.1038/srep36212

Title: Big area additive manufacturing of high performance bonded NdFeB magnets

Journal Article · Mon Oct 31 00:00:00 EDT 2016 · Scientific Reports

DOI:https://doi.org/10.1038/srep36212· OSTI ID:1335023

Li, Ling ^[1]; Tirado, Angelica ^[1]; Nlebedim, I. C. ^[2]; Rios, Orlando ^[1]; Post, Brian ^[1]; Kunc, Vlastimil ^[1]; Lowden, R. R. ^[1]; Lara-Curzio, Edgar ^[1]; Fredette, Robert ^[3]; Ormerod, John ^[3]; Lograsso, Thomas A. ^[2]; Paranthaman, M. Parans ^[1]

Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Ames Lab., Ames, IA (United States)
Magnet Applications, Inc., DuBois, PA (United States)

Additive manufacturing (AM) allows for the production of complex parts with minimum material waste, offering an effective technique for fabricating permanent magnets which frequently involve critical rare earth elements. In this report, we demonstrate a novel method - Big Area Additive Manufacturing (BAAM) to fabricate isotropic near-net-shape Nd-Fe-B bonded magnets with magnetic and mechanical properties comparable or better than those of traditional injection molded magnets. The starting polymer magnet composite pellets consist of 65 vol% isotropic Nd-Fe-B powder and 35 vol% polyamide (Nylon-12). The density of the final magnet product reached 4.8 g/cm³, and the room temperature magnetic properties are: Intrinsic coercivity Hci = 8.65 kOe, Remanence Br = 5.07 kG, and energy product (BH)_max = 5.47 MGOe (43.50 kJ/m³). The temperature dependence of the magnetic properties in the final magnet products is similar to that of the starting material, indicating that the BAAM process did not degrade the magnetic properties. In addition, tension tests performed on four dog-bone shaped specimens yielded an average ultimate tensile strength of 6.60 MPa and an average failure strain of 4.18 %. Scanning electron microscopy images indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binders. Lastly, the present method significantly simplifies manufacturing of near-net-shape bonded magnets, enables efficient use of rare earth elements thus contributing towards enriching the supply of critical materials.

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Research Organization:: Ames Laboratory (AMES), Ames, IA (United States); Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Critical Materials Institute (CMI)

Sponsoring Organization:: USDOE; Work for Others (WFO)

Grant/Contract Number:: AC02-07CH11358; AC05-00OR22725

OSTI ID:: 1335023

Alternate ID(s):: OSTI ID: 1344990

Report Number(s):: IS-J-9103; srep36212

Journal Information:: Scientific Reports, Vol. 6; ISSN 2045-2322

Publisher:: Nature Publishing GroupCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 100 works

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36 MATERIALS SCIENCE
bonded magnets
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magnetic properties
flux loss
mechanical properties
ferromagnetism
magnetic properties and materials

Title: Big area additive manufacturing of high performance bonded NdFeB magnets

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