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

Abstract

Additive manufacturing 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 NdFeB 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 NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm3, and the room temperature magnetic properties are: intrinsic coercivity Hci = 688.4 kA/m, remanence B r = 0.51 T, and energy product (BH) max = 43.49 kJ/m 3 (5.47 MGOe). In addition, tensile 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 of the fracture surfaces indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binder. As a result, the present method significantly simplifies manufacturing of near-net-shape bonded magnets, enables efficient use of rare earth elements thus contributing towards enrichingmore » the supply of critical materials.« less

Authors:
 [1];  [1];  [2];  [1];  [1];  [1];  [1];  [1];  [3];  [3];  [2];  [1]
  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  2. Ames Lab., Ames, IA (United States)
  3. Magnet Applications, Inc., DuBois, PA (United States)
Publication Date:
Research Org.:
Ames Laboratory (AMES), Ames, IA (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Critical Materials Institute (CMI)
Sponsoring Org.:
USDOE; Work for Others (WFO)
OSTI Identifier:
1335023
Alternate Identifier(s):
OSTI ID: 1344990
Report Number(s):
IS-J-9103
Journal ID: ISSN 2045-2322; srep36212
Grant/Contract Number:  
AC02-07CH11358; AC05-00OR22725
Resource Type:
Accepted Manuscript
Journal Name:
Scientific Reports
Additional Journal Information:
Journal Volume: 6; Journal ID: ISSN 2045-2322
Publisher:
Nature Publishing Group
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; bonded magnets; NdFeB; BAAM process; magnetic properties; flux loss; mechanical properties; ferromagnetism; magnetic properties and materials

Citation Formats

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., and Paranthaman, M. Parans. Big area additive manufacturing of high performance bonded NdFeB magnets. United States: N. p., 2016. Web. doi:10.1038/srep36212.
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. Big area additive manufacturing of high performance bonded NdFeB magnets. United States. doi:10.1038/srep36212.
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., and Paranthaman, M. Parans. Mon . "Big area additive manufacturing of high performance bonded NdFeB magnets". United States. doi:10.1038/srep36212. https://www.osti.gov/servlets/purl/1335023.
@article{osti_1335023,
title = {Big area additive manufacturing of high performance bonded NdFeB magnets},
author = {Li, Ling and Tirado, Angelica and Nlebedim, I. C. and Rios, Orlando and Post, Brian and Kunc, Vlastimil and Lowden, R. R. and Lara-Curzio, Edgar and Fredette, Robert and Ormerod, John and Lograsso, Thomas A. and Paranthaman, M. Parans},
abstractNote = {Additive manufacturing 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 NdFeB 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 NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm3, and the room temperature magnetic properties are: intrinsic coercivity Hci = 688.4 kA/m, remanence Br = 0.51 T, and energy product (BH)max = 43.49 kJ/m3 (5.47 MGOe). In addition, tensile 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 of the fracture surfaces indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binder. As a result, 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.},
doi = {10.1038/srep36212},
journal = {Scientific Reports},
number = ,
volume = 6,
place = {United States},
year = {2016},
month = {10}
}

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