Compression Molding and Novel Sintering Treatments for Alnico Type-8 Permanent Magnets in Near-Final Shape with Preferred Orientation

Kassen, Aaron G.; White, Emma M.  H.; Tang, Wei; Hu, Liangfa; Palasyuk, Andriy; Zhou, Lin; Anderson, Iver E.

doi:10.1007/s11837-017-2453-0

Title: Compression Molding and Novel Sintering Treatments for Alnico Type-8 Permanent Magnets in Near-Final Shape with Preferred Orientation

Abstract

We present economic uncertainty in the rare earth (RE) permanent magnet marketplace, as well as in an expanding electric drive vehicle market that favors permanent magnet alternating current synchronous drive motors, motivated renewed research in RE-free permanent magnets like “alnico,” an Al-Ni-Co-Fe alloy. Thus, high-pressure, gas-atomized isotropic type-8H pre-alloyed alnico powder was compression molded with a clean burn-out binder to near-final shape and sintered to density >99% of cast alnico 8 (full density of 7.3 g/cm³). To produce aligned sintered alnico magnets for improved energy product and magnetic remanence, uniaxial stress was attempted to promote controlled grain growth, avoiding directional solidification that provides alignment in alnico 9. Lastly, successful development of solid-state powder processing may enable anisotropically aligned alnico magnets with enhanced energy density to be mass-produced.

Authors:

^[1]; White, Emma M. H. ^[2]; Tang, Wei ^[2]; Hu, Liangfa ^[2]; Palasyuk, Andriy ^[2]; Zhou, Lin ^[2]; Anderson, Iver E. ^[1]

Ames Lab. and Iowa State Univ., Ames, IA (United States). Department of Materials Science and Engineering
Ames Lab. and Iowa State Univ., Ames, IA (United States)

Publication Date:: 2017-07-14

Research Org.:: Ames Lab., Ames, IA (United States)

Sponsoring Org.:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

OSTI Identifier:: 1374730

Report Number(s):: IS-J-9368
Journal ID: ISSN 1047-4838; PII: 2453

Grant/Contract Number:: AC02-07CH11358

Resource Type:: Accepted Manuscript

Journal Name:: JOM. Journal of the Minerals, Metals & Materials Society

Additional Journal Information:: Journal Volume: 69; Journal Issue: 9; Journal ID: ISSN 1047-4838

Publisher:: Springer

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE

Citation Formats


                    Kassen, Aaron G., White, Emma M.  H., Tang, Wei, Hu, Liangfa, Palasyuk, Andriy, Zhou, Lin, and Anderson, Iver E. Compression Molding and Novel Sintering Treatments for Alnico Type-8 Permanent Magnets in Near-Final Shape with Preferred Orientation.  United States: N. p., 2017. 
Web.  doi:10.1007/s11837-017-2453-0.

Copy to clipboard


                    Kassen, Aaron G., White, Emma M.  H., Tang, Wei, Hu, Liangfa, Palasyuk, Andriy, Zhou, Lin, & Anderson, Iver E. Compression Molding and Novel Sintering Treatments for Alnico Type-8 Permanent Magnets in Near-Final Shape with Preferred Orientation.  United States.  https://doi.org/10.1007/s11837-017-2453-0

Copy to clipboard


                    Kassen, Aaron G., White, Emma M.  H., Tang, Wei, Hu, Liangfa, Palasyuk, Andriy, Zhou, Lin, and Anderson, Iver E. Fri .  
"Compression Molding and Novel Sintering Treatments for Alnico Type-8 Permanent Magnets in Near-Final Shape with Preferred Orientation".  United States.  https://doi.org/10.1007/s11837-017-2453-0.  https://www.osti.gov/servlets/purl/1374730.

Copy to clipboard


                    
@article{osti_1374730,

  title        = {Compression Molding and Novel Sintering Treatments for Alnico Type-8 Permanent Magnets in Near-Final Shape with Preferred Orientation},

  author       = {Kassen, Aaron G. and White, Emma M.  H. and Tang, Wei and Hu, Liangfa and Palasyuk, Andriy and Zhou, Lin and Anderson, Iver E.},

  abstractNote = {We present economic uncertainty in the rare earth (RE) permanent magnet marketplace, as well as in an expanding electric drive vehicle market that favors permanent magnet alternating current synchronous drive motors, motivated renewed research in RE-free permanent magnets like “alnico,” an Al-Ni-Co-Fe alloy. Thus, high-pressure, gas-atomized isotropic type-8H pre-alloyed alnico powder was compression molded with a clean burn-out binder to near-final shape and sintered to density >99% of cast alnico 8 (full density of 7.3 g/cm3). To produce aligned sintered alnico magnets for improved energy product and magnetic remanence, uniaxial stress was attempted to promote controlled grain growth, avoiding directional solidification that provides alignment in alnico 9. Lastly, successful development of solid-state powder processing may enable anisotropically aligned alnico magnets with enhanced energy density to be mass-produced.},

  doi          = {10.1007/s11837-017-2453-0},

  journal      = {JOM. Journal of the Minerals, Metals & Materials Society},

  number       = 9,

  volume       = 69,

  place        = {United States},

  year         = {2017},

  month        = {7}

}

Copy to clipboard

Journal Article:

Free Publicly Available Full Text

Accepted Manuscript (DOE)

Publisher's Version of Record

https://doi.org/10.1007/s11837-017-2453-0

Other availability

Search WorldCat to find libraries that may hold this journal

Citation Metrics:

Cited by: 3 works

Citation information provided by
Web of Science

Save / Share:

Export Metadata

Save to My Library

Works referenced in this record:

Effect of Co on the thermal stability and magnetic properties of AlNiCo 8 alloys
journal, May 2014

Liu, Tao; Li, Wei; Zhu, Minggang
Journal of Applied Physics, Vol. 115, Issue 17
DOI: 10.1063/1.4868083

Some relationships between crystal textures and magnetic properties of alnico 8
journal, June 1970

Higuchi, A.; Miyamoto, T.
IEEE Transactions on Magnetics, Vol. 6, Issue 2
DOI: 10.1109/TMAG.1970.1066736

Texture and Magnetic Properties
journal, January 1989

Bunge, H. J.
Textures and Microstructures, Vol. 11, Issue 2-4
DOI: 10.1155/TSM.11.75

Current status and recent topics of rare-earth permanent magnets
journal, January 2011

Sugimoto, S.
Journal of Physics D: Applied Physics, Vol. 44, Issue 6
DOI: 10.1088/0022-3727/44/6/064001

Architecture and magnetism of alnico
journal, August 2014

Zhou, Lin; Miller, M. K.; Lu, Ping
Acta Materialia, Vol. 74
DOI: 10.1016/j.actamat.2014.04.044

Novel pre-alloyed powder processing of modified alnico 8: Correlation of microstructure and magnetic properties
journal, May 2015

Anderson, I. E.; Kassen, A. G.; White, E. M. H.
Journal of Applied Physics, Vol. 117, Issue 17
DOI: 10.1063/1.4916996

Highly tuned gas atomization for controlled preparation of coarse powder. Hochleistungsgasverdüsung für die gezielte Präparation grober Pulver
journal, July 2010

Anderson, I. E.; Byrd, D.; Meyer, J.
Materialwissenschaft und Werkstofftechnik, Vol. 41, Issue 7, p. 504-512
DOI: 10.1002/mawe.201000636

Prospects for Non-Rare Earth Permanent Magnets for Traction Motors and Generators
journal, June 2012

Kramer, M. J.; McCallum, R. W.; Anderson, I. A.
JOM, Vol. 64, Issue 7
DOI: 10.1007/s11837-012-0351-z

Similar Records in DOE PAGES and OSTI.GOV collections:

Development of controlled solid-state alignment for alnico permanent magnets in near-final shape

Journal Article Anderson, Iver E. ; Kassen, Aaron G. ; White, Emma M. H. ; ... - AIP Advances

The 2011 price shock in the rare earth (RE) permanent magnet (PM) marketplace precipitated realization of extremely poor RE supply diversity and drove renewed research in RE-free permanent magnets such as “alnico.” Essentially, alnico is an Al-Ni-Co-Fe alloy with high magnetic saturation and T_C, but low coercivity. It also was last researched extensively in the 1970’s. Currently alnico “9” magnets with the highest energy product (10MGOe) are manufactured by directional solidification to make highly aligned anisotropic magnets. This work developed novel powder processing techniques to improve on unaligned anisotropic alnico “8H” with elevated coercivity. Gas atomization was used to producemore »« less
Cited by 2
https://doi.org/10.1063/1.4973843
Manufacturing of Advanced Alnico Magnets for Energy Efficient Traction Drive Motors CRADA Final Report

Technical Report Anderson, Iver

The primary theme of this Technology Commercialization Fund (TCF) project was refining the pre-alloyed powder processing approach (with alnico 8, modified for higher coercivity) of that came out of the previous Development of Radically Enhanced alnico Magnets (DREaM) project to permit full size net-shape alnico magnets to be produced in a reproducible manner that could allow testing in an advanced Permanent Magnet (PM) drive motor. Previously, a lack of sufficient coercivity in alnico magnets limits their energy product and their application in automotive traction drive motors, despite their high temperature stability. Use of enhanced sintered alnico magnets, instead of raremore »« less
https://doi.org/10.2172/1574906

Full Text Available
Novel mechanisms for solid-state processing and grain growth with microstructure alignment in alnico-8 based permanent magnets

Journal Article Kassen, Aaron G. ; White, Emma M. H. ; Hu, Liangfa ; ... - AIP Advances

An estimated 750,000 new hybrid electric and plug-in battery vehicles, most with permanent magnet synchronous alternating current (PMAC) drive motors, took to the road in 2016 alone. Accompanied by 40% year over year growth in the EV market significant challenges exist in producing large quantities of permanent magnets (on the order of tens of millions) for reliable, low-cost traction motors [IE Agency, Energy Technology Perspectives (2017)]. Since the rare earth permanent magnet (REPM) market is essentially 100% net import reliant in the United States and has proven to have an unstable cost and supply structure in recent years, a replacementmore »« less
https://doi.org/10.1063/1.5007850

Full Text Available
Novel pre-alloyed powder processing of modified alnico 8: Correlation of microstructure and magnetic properties

Journal Article Anderson, I. E., E-mail: andersoni@ameslab.gov ; Kassen, A. G. ; White, E. M. H. ; ... - Journal of Applied Physics

Progress is reviewed on development of an improved near-final bulk magnet fabrication process for alnico 8, as a non-rare earth permanent magnet with promise for sufficient energy density and coercivity for electric drive motors. This study showed that alnico bulk magnets in near-final shape can be made by simple compression molding from spherical high purity gas atomized pre-alloyed powder. Dwell time at peak sintering temperature (1250 °C) greatly affected grain size of the resulting magnet alloys. This microstructure transformation was demonstrated to be useful for gaining partially aligned magnetic properties and boosting energy product. While a route to increased coercivity wasmore »« less
https://doi.org/10.1063/1.4916996
Novel pre-alloyed powder processing of modified alnico 8: Correlation of microstructure and magnetic properties

Journal Article Anderson, I. E. ; Kassen, A. G. ; White, E. M. H. ; ... - Journal of Applied Physics

Progress is reviewed on development of an improved near-final bulk magnet fabrication process for alnico 8, as a non-rare earth permanent magnet with promise for sufficient energy density and coercivity for electric drive motors. This study showed that alnico bulk magnets in near-final shape can be made by simple compression molding from spherical high purity gas atomized pre-alloyed powder. Dwell time at peak sintering temperature (1250°C) greatly affected grain size of the resulting magnet alloys. This microstructure transformation was demonstrated to be useful for gaining partially aligned magnetic properties and boosting energy product. Furthermore, while a route to increased coercivitymore »« less
Cited by 6
https://doi.org/10.1063/1.4916996

Full Text Available

Similar Records

Title: Compression Molding and Novel Sintering Treatments for Alnico Type-8 Permanent Magnets in Near-Final Shape with Preferred Orientation

Abstract

Citation Formats

Effect of Co on the thermal stability and magnetic properties of AlNiCo 8 alloys journal, May 2014

Some relationships between crystal textures and magnetic properties of alnico 8 journal, June 1970

Texture and Magnetic Properties journal, January 1989

Current status and recent topics of rare-earth permanent magnets journal, January 2011

Architecture and magnetism of alnico journal, August 2014

Novel pre-alloyed powder processing of modified alnico 8: Correlation of microstructure and magnetic properties journal, May 2015

Highly tuned gas atomization for controlled preparation of coarse powder. Hochleistungsgasverdüsung für die gezielte Präparation grober Pulver journal, July 2010

Prospects for Non-Rare Earth Permanent Magnets for Traction Motors and Generators journal, June 2012

Effect of Co on the thermal stability and magnetic properties of AlNiCo 8 alloys
journal, May 2014

Some relationships between crystal textures and magnetic properties of alnico 8
journal, June 1970

Texture and Magnetic Properties
journal, January 1989

Current status and recent topics of rare-earth permanent magnets
journal, January 2011

Architecture and magnetism of alnico
journal, August 2014

Novel pre-alloyed powder processing of modified alnico 8: Correlation of microstructure and magnetic properties
journal, May 2015

Highly tuned gas atomization for controlled preparation of coarse powder. Hochleistungsgasverdüsung für die gezielte Präparation grober Pulver
journal, July 2010

Prospects for Non-Rare Earth Permanent Magnets for Traction Motors and Generators
journal, June 2012