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

Abstract

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 preparingmore » near-net-shape bonded magnets for various magnetic applications.« less

Authors:
 [1];  [2];  [1];  [3];  [1];  [4];  [4];  [5];  [6]
+ Show Author Affiliations
  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)
Publication Date:
Research Org.:
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Critical Materials Institute (CMI)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
OSTI Identifier:
1260082
Grant/Contract Number:  
AC05-00OR22725
Resource Type:
Accepted Manuscript
Journal Name:
JOM. Journal of the Minerals, Metals & Materials Society
Additional Journal Information:
Journal Volume: 68; Journal Issue: 7; Journal ID: ISSN 1047-4838
Publisher:
Springer
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE

Citation Formats

Paranthaman, M. Parans, Shafer, Christopher S., Elliott, Amy M., Siddel, Derek H., McGuire, Michael A., Springfield, Robert M., Martin, Josh, Fredette, Robert, and Ormerod, John. Binder Jetting: A Novel NdFeB Bonded Magnet Fabrication Process. United States: N. p., 2016. Web. doi:10.1007/s11837-016-1883-4.
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Paranthaman, M. Parans, Shafer, Christopher S., Elliott, Amy M., Siddel, Derek H., McGuire, Michael A., Springfield, Robert M., Martin, Josh, Fredette, Robert, & Ormerod, John. Binder Jetting: A Novel NdFeB Bonded Magnet Fabrication Process. United States. https://doi.org/10.1007/s11837-016-1883-4
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Paranthaman, M. Parans, Shafer, Christopher S., Elliott, Amy M., Siddel, Derek H., McGuire, Michael A., Springfield, Robert M., Martin, Josh, Fredette, Robert, and Ormerod, John. Tue . "Binder Jetting: A Novel NdFeB Bonded Magnet Fabrication Process". United States. https://doi.org/10.1007/s11837-016-1883-4. https://www.osti.gov/servlets/purl/1260082.
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@article{osti_1260082,
title = {Binder Jetting: A Novel NdFeB Bonded Magnet Fabrication Process},
author = {Paranthaman, M. Parans and Shafer, Christopher S. and Elliott, Amy M. and Siddel, Derek H. and McGuire, Michael A. and Springfield, Robert M. and Martin, Josh and Fredette, Robert and Ormerod, John},
abstractNote = {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.},
doi = {10.1007/s11837-016-1883-4},
journal = {JOM. Journal of the Minerals, Metals & Materials Society},
number = 7,
volume = 68,
place = {United States},
year = {Tue Apr 05 00:00:00 EDT 2016},
month = {Tue Apr 05 00:00:00 EDT 2016}
}
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https://doi.org/10.1007/s11837-016-1883-4
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    Works referencing / citing this record:

    Big Area Additive Manufacturing of High Performance Bonded NdFeB Magnets
    journal, October 2016

    • Li, Ling; Tirado, Angelica; Nlebedim, I. C.
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    Net Shape 3D Printed NdFeB Permanent Magnet : Net Shape 3D Printed NdFeB Permanent Magnet
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    A ReaxFF molecular dynamics study of molecular-level interactions during binder jetting 3D-printing
    journal, January 2019

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    Topology optimized and 3D printed polymer-bonded permanent magnets for a predefined external field
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    • DOI: 10.1063/1.4997441

    3D Printing of Functional Assemblies with Integrated Polymer-Bonded Magnets Demonstrated with a Prototype of a Rotary Blood Pump
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    • von Petersdorff-Campen, Kai; Hauswirth, Yannick; Carpenter, Julia
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    • DOI: 10.3390/app8081275

    Processing of Alnico Magnets by Additive Manufacturing
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    • White, Emma; Rinko, Emily; Prost, Timothy
    • Applied Sciences, Vol. 9, Issue 22
    • DOI: 10.3390/app9224843

    Influence of Melt-Pool Stability in 3D Printing of NdFeB Magnets on Density and Magnetic Properties
    journal, December 2019

    • Skalon, Mateusz; Görtler, Michael; Meier, Benjamin
    • Materials, Vol. 13, Issue 1
    • DOI: 10.3390/ma13010139

    A review on recent developments in binder jetting metal additive manufacturing: materials and process characteristics
    journal, September 2019

    Hybrid Materials for Functional 3D Printing
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    • Cooperstein, Ido; Sachyani‐Keneth, Ela; Shukrun‐Farrell, Efrat
    • Advanced Materials Interfaces, Vol. 5, Issue 22
    • DOI: 10.1002/admi.201800996

    3D printing of functional assemblies with integrated polymer-bonded magnets demonstrated with a prototype of a rotary blood pump
    text, January 2018

    • Von Petersdorff-Campen, Kai; Hauswirth, Yannick; Carpenter, Julia
    • MDPI
    • DOI: 10.21256/zhaw-4693

    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

    Big Area Additive Manufacturing of High Performance Bonded NdFeB Magnets
    journal, October 2016

    • Li, Ling; Tirado, Angelica; Nlebedim, I. C.
    • Scientific Reports, Vol. 6, Issue 1
    • DOI: 10.1038/srep36212

    Influence of Melt-Pool Stability in 3D Printing of NdFeB Magnets on Density and Magnetic Properties
    journal, December 2019

    • Skalon, Mateusz; Görtler, Michael; Meier, Benjamin
    • Materials, Vol. 13, Issue 1
    • DOI: 10.3390/ma13010139
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