NOVel, critical materials free, high Anisotropy phases for permanent MAGnets, by design (NOVAMAG)
by José Manuel Barandiarán of Basque Center for Materials, Applications and Nanostructures (BCMaterials)

The NOVAMAG (EU RIA) project aims to create novel, critical materials free, permanent magnets with high anisotropy phases. NOVAMAG has developed an automated large computational screening followed by experimental screening of new and novel intermetallic compounds with uniaxial structures (with high saturation magnetisation, magnetocrystalline anisotropy and Curie temperature), which can be used for the rapid development of high performance permanent magnets without the use of critical raw materials (CRM).

Theoretical characterization of new phases for permanent magnets
by Heike Herper of Uppsala University

Predicting materials properties and identifying new phases with tailored properties from computational simulations has become an inherent tool of materials design. Within the NOVAMAG project we have used two different routes: high throughput calculations to identify to date unknown phases and optimizing known phases in view of their magnetic performance. The calculations were performed using ab initio electronic structure calculations which give access to key properties such as saturation magnetization, magnetocrystalline anisotropy, and magnetic transition temperature and allow to investigate the structural stability of the phases. Here examples for both types of studies will be presented. Showing the optimization of RE-lean phases by modifying the composition [JALCOM 786, 969 (2019)] and presenting a high throughput study to identify novel hard magnetic phases based on transition metals [Comp. Mater. Sci. 168, 188 (2019)]. Predicted phases can serve as starting point for further investigations e.g. micromagnetic simulations or experiments [Phys. Rev. B 99, 024421 (2019)].

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Modelling of microstructure for optimum hard magnetic properties
by Thomas Schrefl of Department for Integrated Sensor Systems, Danube University Krems, Austria

The development of permanent magnets containing less or no rare-earth elements is linked to profound knowledge of the coercivity mechanism. Prerequisites for a promising permanent magnet material are a high spontaneous magnetization and a sufficiently high magnetic anisotropy. In addition to the intrinsic magnetic properties the microstructure of the magnet plays a significant role in establishing coercivity. The influence of the microstructure on coercivity, remanence, and energy density product can be understood by using micromagnetic simulations. With advances in computer hardware and numerical methods, hysteresis curves of magnets can be computed quickly so that the simulations can readily provide guidance for the development of permanent magnets.

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Experimental screening of theoretically predicted phases
by Dimitris Niarchos of National Center of Scientific Research “Demokritos"

Combinatorial and high-throughput (CHT) materials science techniques represent a powerful approach to rapidly screen new compounds and accelerate materials development. CHT methods are based on: i) fabrication of materials libraries (multi-element compositional spreads), ii) high-throughput and spatially resolved characterization techniques, and iii) data analysis/mining for processing high volume data. CHT methods reduce the cost and time of materials Research & Development, effectively addressing the pressing issues arising on materials science. We have used this approach in thin films and in bulk to realize theoretically predicted structures . Examples FeNi(X2) (X2=Ag, Bi) , (Fe,Co)100-x-yMx(X1)y , where x+y < 25 and rare earth- lean RFe12-x (X5)x, (R= Ce, Nd, Sm and X5= C, N)

Fabrication of New Phases with High Coercivity
by Bahar Fayyazi of Technische Universität Darmstadt

Large variety of materials were studied using advanced theoretical and computational methods and the stability and magnetic properties of them were investigated. The potential material classes with hard magnetic properties were chosen to be synthesized and their intrinsic magnetic properties were carefully characterized. Three material classes, Nd-based and Sm-based 1:12 and MnAl systems were selected as material candidates for development of next generation rare-earth free/lean permanent magnets. In order to design an optimal microstructure and consequently inducing high coercivity in the bulk magnets, different novel processing routs such as sintering, melt spinning, hot deformation, additive manufacturing, and etc. were applied and the manufacturing conditions for obtaining desirable magnetic properties were optimized.

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Securing the Supply Chain of Rare-Earth Elements for Nd-Fe-B Type Magnets
by Jürgen Gassmann of Fraunhofer Research Institution Materials Recycling and Resource Strategies IWKS

Whenever it comes to applications requiring magnets of highest energy densities, like in e-mobility, wind turbines, robotics etc. rare earth (RE) permanent magnets based on Nd-Fe-B are the material choice. With their outstanding performance they are key components in numerous applications and often not substitutable without performance losses. The transition in energy and transportation sectors as well as automatization will increase significantly the demand for efficient magnet material in the near future. The required RE elements are mainly mined in Asia and Australia, with China being by far the dominating player. For Europe, being deprived in RE mineral resources and strategic metals in general and hosting companies producing goods further along the value chain a stable supply of RE elements is highly important. One way to lower the supply risk for Europe is to make use of the magnet material already circulating in the market (the technosphere): either by reprocessing back to the individual RE elements or their oxides, or by employing functional recycling, i.e. refeeding the permanent magnet intermetallic compound back into the process chain to avoid the costly and energy-intensive separation steps. A second pathway to lower the supply risk is the use of non-Chinese RE resources, hence establish a second source in the market. In this presentation, we highlight current RE criticality aspects and demonstrate how new fully dense sintered, hot-deformed and anisotropic polymer bonded permanent magnets of good quality can be processed from recycled scrap magnet material – at lower economic and ecological costs. Moreover we highlight the project REGINA, which is a project to develop a competitive Nd-Fe-B magnet from Brazilian resources.

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Eddy current reduction by Snake line
by Patrick Aeschlimann of BOMATEC AG

Presentation of a new production process patented by Bomatec in order to reduce the eddy current losses in the permanent magnets. (sintered NdFeB and SmCo materials)

Technology Trends in Prototype Production of Stator and Rotor Stacks
by Philipp Bucher of LCD LaserCut AG

First our company is presented in order having a brief idea what we are doing and what the focus is on. Then the presentation is going to show the requirements and trends in the prototype production of stator and rotor stack production and how have we managed to meet those in terms of technology.

A UK Magnetics Society Success Story
by Rupert Cruise of Magway

Urbanisation is an unstoppable global trend. European-wide, cities are home to over 70% of the population, and account for 85% of GDP. Properly planned and managed transport infrastructure is essential to avoid overcrowding, congestion and pollution. Magway is a highly automated, small-footprint, high-throughput, solution for the transport of goods, parcels, and groceries, whereby small, lightweight, unmanned vehicles travel within enclosed guideways, moving items rapidly, securely, reliably, and sustainably. Magway’s propulsion system uses linear synchronous motors (LSMs), which enables the vehicles to be lightweight because the motor stator windings are part of the guideway. The vehicles contain an array of neodymium magnets. LSMs contain no moving parts, so are highly reliable. Maintenance requirements are therefore low, and the system can be enclosed, making it safe, secure, and invulnerable to adverse weather conditions. Because the vehicles are lightweight and automated, the system is energy efficient and eliminates the driver (the most expensive aspect of road transport), providing a zero-emissions, faster, cheaper, and more reliable transport solution for e-commerce retailers and operators of logistics networks.

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Post Assembly of Halbach PM Rotor
by Chris Riley of Bunting Magnetics Europe

Including Static and Rotating systems, focusing on the benefits of Halbach design within these systems. The presentation will take a detailed look at the regions that do not saturate fully and how we are able to generate bespoke magnet data for these regions and utilise this to generate a real world model of the system. In addition to design considerations for engineers to facilitate post assembly magnetising we will look at the down stream advantages of this process including the obvious reduction in Health and Safety risk as well as the time saved in assembly, the ease of operations like machining, grinding and balancing and the utilisation of any banding materials to their fullest potential without a limit on magnet killing temperature effects.

Raw Material Efficient Production Techniques
by Christoph Brombacher of Vacuumschmelze GmbH & Co KG

Many high performance permanent magnets depend on rare earth elements, which are predominantly supplied by China. Potential negative impacts on the rare earth supply chain by the expanding trade war between China and the US have recently been discussed. Efficient production techniques as net-shape production, fine-grained-material and grain-boundary-diffusion are methods to minimize these supply risks for Nd-Fe-B based magnet grades. In addition, the recent progress on high remanent Sm2Co17 based magnet grades and its potential as a Dy-free alternative for high temperature applications will be discussed.

PM Rotors In-Situ Magnetisation for Power Train Motors
by Federico Russo of Laboratorio Elettrofisico

PM Brushless motors are the first choice for electric and hybrid vehicles. One part of the motor is the inductor, which provides the magnetic field by means of series of permanent magnets. Until a couple of years ago, motor producers used to magnetize the magnets before their insertion in the rotor. Heavy industrial duty cycle, troubles in handling pre-magnetized magnets, and the effect of hot glue on pre-magnetized magnets quality all made it necessary to magnetize the entire rotors after assembly. It is known as in-situ magnetization. It comprises the magnetization, quality control, and handling automation. Here, the most recent development on EV PM rotors magnetization is described, with focus on design, development, MP equipment, and related automation systems production.

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PM Magnetisation Model for Mixed Anisotropic and Isotropic Magnets
by Govind Bisht of Laboratorio Elettrofisico

Widely used permanent magnets are alloys made from powdered ferrite oxides or rare earth compounds. Powdered grains are milled at the desired grade, then pressed and sintered or mixed with plastic and injected. During pressing or injection, often, a strong magnetic field keeps the grains oriented to obtain anisotropic magnets. This process is not ideal: therefore, anisotropic magnets have certain percentage of isotropy associated with them. The presence of isotropy in an anisotropic magnet for what concerns the magnetization process has been described here. In addition, the modelling of such supposedly anisotropic magnet having certain isotropy level using FEA; the definition and measurement of isotropy present; along with different magnetization approaches according to the effect this isotropy ratio would have in the final application is presented here.

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Computer Simulation Techniques: Evolution and Perspectives
by Alessandro Tassi of Spin Applicazioni Magnetiche S.r.l.

Nowadays in industrial R&D departments and technical offices, we are used to considering computer simulation as an expected procedure for the innovation of the company. Why, when, and how did this occur? What, today, are the perspectives for simulation techniques? We will focus on some of the historical steps of the computer simulation, to understand how we can optimize this benefit and how it could evolve.

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Shielding Effects During Permanent Magnets Magnetisation Process
by Matteo Pistaffa of Laboratorio Elettrofisico

The magnetic shielding is the reduction of the magnetic field by means of a material, namely a shield. Different mechanisms are responsible for the rise of this effect, as the field can be reflected or driven through the shield, according to the frequency of the magnetic field itself. The “skin depth” of the field through the shield is the key parameter controlling the phenomenon. It depends on the frequency of the magnetic field and on the resistivity and the magnetic permeability of the material of the shield. A conscious choice of these properties allows us to exploit the effect in many applications. This work, in particular, analyzed the use of the effect to shield magnetizing inductors and, sometimes, to improve their efficiency. Then, some examples are presented, which are related to the magnetization of loudspeakers and DC motor housings, in which the permanent magnets are behind bodies that shield the magnetizing field – thus, strategies are needed to let the magnetizing field penetrate such shields.

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Laboratorio Elettrofisico’s 60 Years of Experience in Magnetic Measurements
by Andrea Del Prete of Laboratorio Elettrofisico

The 60 years of Laboratorio Elettrofisico’s activities in the magnetic technology give rise to the occasion to see how magnetic measurements, standards and instrumentation followed the evolution of the materials and necessities of the industry. The wide variety of magnetic materials and their different uses demand measuring techniques to provide information that is fundamental from the beginning of the project of a magnetic device to its quality control in production. The measurement principles and modern standard techniques to measure magnetic materials are described from the point of view of the instrumentation developed by Laboratorio Elettrofisico, from the past to the present day.

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Rare Earth Permanent Magnets: A journey towards sustainability
by Badrinath Veluri of GRUNDFOS A/S

Sustainability and Transparency is a quite a big question when it comes to the Rare Earths, yet these materials contribute a lot of positive impact during the use phase in many applications they tend to have a considerable environmental impact in the upstream activities when they are not handled properly. The time is now for the industry to work for one world in making these materials sustainable by doing proper assessments and formation of standards that allows the downstream players to contribute to the sustainability and to the future generations.

PM-Wire: A New Permanent Magnet (PM) Technology
by Mark Senti of AML

AML is developing of a new approach for the manufacturing and application of permanent magnets. Named PM-WireTM, the technology allows highly automated, safe, mass-produced magnets, including complex and “wire like” shape forms. As a result, the magnets and final end-use product such as motors will be lower cost with significant increase in reliability and performance. This presentation will provide an overview of the PM-Wire manufacturing process and how it is uniquely applied to the end-use application and its potential impact on the global magnet market.

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Extraction and Recycling of Rare Earth Magnets: Magnetic Materials Group Pilot Plant Development
by Lydia Pickering of University of Birmingham

The presentation will provide an overview of the activities performed by the Magnetic Materials Group at the University of Birmingham on recycling rare earth permanent magnets based on NdFeB and will detail one of the main projects we are currently involved with, SUSMAGPRO (Sustainable Recovery, Reprocessing and Reuse of Rare-Earth Magnets in a Circular Economy). The aim of SUSMAGPRO is to identify, separate, reprocess and reuse RE-magnets at a pilot scale across Europe so the final part of the talk will discuss the plans for the pilot plant development at the University of Birmingham.

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Alternative magnet production way by hot pressing - a pump manufacturer becomes a magnet producer
by Martin Krengel of WILO SE

After a short company presentation, description and video presentation of the WILO production facilities. Explanation of the advantages and disadvantages of the hot pressing process. Outlook on the possibilities that the process could still offer.