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

Abstract

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.more »« less

Authors:

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)

Publication Date:: Mon Oct 31 00:00:00 EDT 2016

Research Org.:: Ames Laboratory (AMES), Ames, IA (United States); Oak Ridge National Laboratory (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.

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                    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.  https://doi.org/10.1038/srep36212

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                    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.  https://doi.org/10.1038/srep36212.  https://www.osti.gov/servlets/purl/1335023.

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@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 (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.},

  doi          = {10.1038/srep36212},

  journal      = {Scientific Reports},

  number       = ,

  volume       = 6,

  place        = {United States},

  year         = {Mon Oct 31 00:00:00 EDT 2016},

  month        = {Mon Oct 31 00:00:00 EDT 2016}

}

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Magnetic properties of rare‐earth‐iron‐boron permanent magnet materials journal, April 1985

Additive manufacturing: technology, applications and research needs journal, May 2013

3D print of polymer bonded rare-earth magnets, and 3D magnetic field scanning with an end-user 3D printer journal, October 2016

Mechanical properties of polyphenylene-sulfide (PPS) bonded Nd–Fe–B permanent magnets journal, October 2003

Applying Permanent Magnets journal, January 1996

High-Energy Extrusion-Molded Nd-Fe-B Magnets. [高性能押出成形Ｎｄ‐Ｆｅ‐Ｂ系ボンド磁石] journal, January 1994

3D Print of Polymer Bonded Rare-Earth Magnets, and 3D Magnetic Field Scanning With an End-User 3D Printer text, January 2016

Binder Jetting: A Novel NdFeB Bonded Magnet Fabrication Process journal, April 2016

Epoxy resin effect on anisotropic Nd–Fe–B rubber-bonded magnets performance journal, January 2011

Research on anisotropic bonded Nd–Fe–B magnets by 2-step compaction process journal, March 2016

Additive Manufacturing of a Microbial Fuel Cell—A detailed study journal, November 2015

Pr‐Fe and Nd‐Fe‐based materials: A new class of high‐performance permanent magnets (invited) journal, March 1984

New material for permanent magnets on a base of Nd and Fe (invited) journal, March 1984

Magnetic properties of rare‐earth‐iron‐boron permanent magnet materials journal, April 1985

Controlling the properties of high energy density permanent magnetic materials by different processing routes journal, August 2000

The exchange-spring magnet: a new material principle for permanent magnets journal, July 1991

Net Shape 3D Printed NdFeB Permanent Magnet : Net Shape 3D Printed NdFeB Permanent Magnet journal, April 2017

Photocurable pentaerythritol triacrylate/lithium phenyl‐2,4,6‐trimethylbenzoylphosphinate‐based ink for extrusion‐based 3D printing of magneto‐responsive materials journal, February 2020

Mechanochemically Processed Nd−Fe−Co−Cr−B Nanoparticles with High Coercivity and Reduced Spin Reorientation Transition Temperature journal, June 2018

Additive manufacturing of magnetic shielding and ultra-high vacuum flange for cold atom sensors journal, January 2018

Topology optimized and 3D printed polymer-bonded permanent magnets for a predefined external field journal, August 2017

Recycled Sm-Co bonded magnet filaments for 3D printing of magnets journal, May 2018

Topology optimization of reduced rare-earth permanent magnet arrays with finite coercivity journal, May 2018

An electrodynamic energy harvester with a 3D printed magnet and optimized topology journal, January 2019

High energy product of MnBi by field annealing and Sn alloying journal, December 2019

Development of permanent magnet MnAlC/polymer composites and flexible filament for bonding and 3D-printing technologies journal, May 2018

Production of complex shape magnets using additive manufacturing: A state-of-the-art analysis journal, November 2019

3D Printing of Functional Assemblies with Integrated Polymer-Bonded Magnets Demonstrated with a Prototype of a Rotary Blood Pump journal, August 2018

Processing of Alnico Magnets by Additive Manufacturing journal, November 2019

Development and Characterization of Stable Polymer Formulations for Manufacturing Magnetic Composites journal, January 2020

Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives journal, May 2018

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

Investigation of Energy Requirements and Environmental Performance for Additive Manufacturing Processes journal, October 2018

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

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

Additive manufacturing of magnetic shielding and ultra-high vacuum flange for cold atom sensors preprint, January 2017

Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets journal, November 2019

3D Printing of Polymer-Bonded Rare-Earth Magnets With a Variable Magnetic Compound Fraction for a Predefined Stray Field journal, August 2017

Additive Manufacturing and Topology Optimization of Magnetic Materials for Electrical Machines—A Review journal, January 2021

Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives journal, May 2018

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

Imaging three-dimensional magnetic systems with X-rays text, January 2019

3D Printing of ABS Barium Ferrite Composites text, January 2020

Permanent magnets: Plugging the gap
journal, September 2012

Additive Manufacturing of a Microbial Fuel Cell—A detailed study
journal, November 2015

Epoxy resin effect on anisotropic Nd–Fe–B rubber-bonded magnets performance
journal, January 2011

Effect of process on the magnetic and mechanical properties of Nd–Fe–B bonded magnets
journal, April 2009

The exchange-spring magnet: a new material principle for permanent magnets
journal, July 1991

Research on anisotropic bonded Nd–Fe–B magnets by 2-step compaction process
journal, March 2016

Hard Magnetic Materials: A Perspective
journal, December 2011

Mechanical properties of Nylon bonded Nd–Fe–B permanent magnets
journal, February 2003

Pr‐Fe and Nd‐Fe‐based materials: A new class of high‐performance permanent magnets (invited)
journal, March 1984

New material for permanent magnets on a base of Nd and Fe (invited)
journal, March 1984

Binder Jetting: A Novel NdFeB Bonded Magnet Fabrication Process
journal, April 2016

Controlling the properties of high energy density permanent magnetic materials by different processing routes
journal, August 2000

Recent development in bonded NdFeB magnets
journal, February 2002

Relationships between crystal structure and magnetic properties in ${Nd}_{2}$ ${Fe}_{14}$ B
journal, April 1984

High-Energy Extrusion-Molded Nd-Fe-B Magnets
journal, September 1994

Bonded permanent magnets: Current status and future opportunities (invited)
journal, April 1997

Magnetic properties of anisotropic Nd–Fe–B resin bonded magnets
journal, October 2006

Magnetic properties of rare‐earth‐iron‐boron permanent magnet materials
journal, April 1985

Additive manufacturing: technology, applications and research needs
journal, May 2013

3D print of polymer bonded rare-earth magnets, and 3D magnetic field scanning with an end-user 3D printer
journal, October 2016

Mechanical properties of polyphenylene-sulfide (PPS) bonded Nd–Fe–B permanent magnets
journal, October 2003

Applying Permanent Magnets
journal, January 1996

High-Energy Extrusion-Molded Nd-Fe-B Magnets. [高性能押出成形Ｎｄ‐Ｆｅ‐Ｂ系ボンド磁石]
journal, January 1994

3D Print of Polymer Bonded Rare-Earth Magnets, and 3D Magnetic Field Scanning With an End-User 3D Printer
text, January 2016

Binder Jetting: A Novel NdFeB Bonded Magnet Fabrication Process
journal, April 2016

Epoxy resin effect on anisotropic Nd–Fe–B rubber-bonded magnets performance
journal, January 2011

Research on anisotropic bonded Nd–Fe–B magnets by 2-step compaction process
journal, March 2016

Additive Manufacturing of a Microbial Fuel Cell—A detailed study
journal, November 2015

Pr‐Fe and Nd‐Fe‐based materials: A new class of high‐performance permanent magnets (invited)
journal, March 1984

New material for permanent magnets on a base of Nd and Fe (invited)
journal, March 1984

Magnetic properties of rare‐earth‐iron‐boron permanent magnet materials
journal, April 1985

Controlling the properties of high energy density permanent magnetic materials by different processing routes
journal, August 2000

The exchange-spring magnet: a new material principle for permanent magnets
journal, July 1991

Net Shape 3D Printed NdFeB Permanent Magnet : Net Shape 3D Printed NdFeB Permanent Magnet
journal, April 2017

Photocurable pentaerythritol triacrylate/lithium phenyl‐2,4,6‐trimethylbenzoylphosphinate‐based ink for extrusion‐based 3D printing of magneto‐responsive materials
journal, February 2020

Mechanochemically Processed Nd−Fe−Co−Cr−B Nanoparticles with High Coercivity and Reduced Spin Reorientation Transition Temperature
journal, June 2018

Additive manufacturing of magnetic shielding and ultra-high vacuum flange for cold atom sensors
journal, January 2018

Topology optimized and 3D printed polymer-bonded permanent magnets for a predefined external field
journal, August 2017

Recycled Sm-Co bonded magnet filaments for 3D printing of magnets
journal, May 2018

Topology optimization of reduced rare-earth permanent magnet arrays with finite coercivity
journal, May 2018

An electrodynamic energy harvester with a 3D printed magnet and optimized topology
journal, January 2019

High energy product of MnBi by field annealing and Sn alloying
journal, December 2019

Development of permanent magnet MnAlC/polymer composites and flexible filament for bonding and 3D-printing technologies
journal, May 2018

Production of complex shape magnets using additive manufacturing: A state-of-the-art analysis
journal, November 2019

3D Printing of Functional Assemblies with Integrated Polymer-Bonded Magnets Demonstrated with a Prototype of a Rotary Blood Pump
journal, August 2018

Processing of Alnico Magnets by Additive Manufacturing
journal, November 2019

Development and Characterization of Stable Polymer Formulations for Manufacturing Magnetic Composites
journal, January 2020

Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives
journal, May 2018

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

Investigation of Energy Requirements and Environmental Performance for Additive Manufacturing Processes
journal, October 2018

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

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

Additive manufacturing of magnetic shielding and ultra-high vacuum flange for cold atom sensors
preprint, January 2017

Binder jet additive manufacturing method to fabricate near net shape crack-free highly dense Fe-6.5 wt.% Si soft magnets
journal, November 2019

3D Printing of Polymer-Bonded Rare-Earth Magnets With a Variable Magnetic Compound Fraction for a Predefined Stray Field
journal, August 2017

Additive Manufacturing and Topology Optimization of Magnetic Materials for Electrical Machines—A Review
journal, January 2021

Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives
journal, May 2018

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

Imaging three-dimensional magnetic systems with X-rays
text, January 2019

3D Printing of ABS Barium Ferrite Composites
text, January 2020