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Magnetic feed material and its use in producing bonded permanent magnets by additive manufacturing

Patent ·
OSTI ID:1735221
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A method for producing magnet-polymer pellets useful as a feedstock in an additive manufacturing process, comprising: (i) blending thermoplastic polymer and hard magnetic particles; (ii) feeding the blended magnet-polymer mixture into a pre-feed hopper that feeds directly into an inlet of a temperature-controlled barrel extruder; (iii) feeding the blended magnet-polymer mixture into the barrel extruder at a fixed feed rate of 5-20 kg/hour, wherein the temperature at the outlet is at least to no more than 10° C. above a glass transition temperature of the blended magnet-polymer mixture; (iv) feeding the blended magnet-polymer mixture directly into an extruding die; (v) passing the blended magnet-polymer mixture through the extruding die at a fixed speed; and (vi) cutting the magnet-polymer mixture at regular intervals as the mixture exits the extruding die at the fixed speed. The use of the pellets as feed material in an additive manufacturing process is also described.
Research Organization:
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Sponsoring Organization:
USDOE
DOE Contract Number:
AC05-00OR22725
Assignee:
UT-Battelle, LLC (Oak Ridge, TN)
Patent Number(s):
10,766,181
Application Number:
15/796,110
OSTI ID:
1735221
Country of Publication:
United States
Language:
English

References (11)

Binder Jetting: A Novel NdFeB Bonded Magnet Fabrication Process journal April 2016
Recent development in bonded NdFeB magnets journal February 2002
Mechanical properties of Nylon bonded Nd–Fe–B permanent magnets journal February 2003
Fabrication of highly dense isotropic Nd-Fe-B nylon bonded magnets via extrusion-based additive manufacturing journal May 2018
Studies on in situ magnetic alignment of bonded anisotropic Nd-Fe-B alloy powders journal January 2017
A novel method combining additive manufacturing and alloy infiltration for NdFeB bonded magnet fabrication journal September 2017
Additive manufacturing of near-net-shape bonded magnets: Prospects and challenges journal July 2017
Big Area Additive Manufacturing of High Performance Bonded NdFeB Magnets journal October 2016
3D print of polymer bonded rare-earth magnets, and 3D magnetic field scanning with an end-user 3D printer journal October 2016
Direct-write 3D printing of NdFeB bonded magnets journal December 2016
Additive Manufacturing of Near-net Shaped Permanent Magnets report July 2016

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36 MATERIALS SCIENCE