Mind the Gap: The Case for Developing L10 FeNi (Tetrataenite) as a ‘Hard’ Permanent Magnet
by Christopher Woodgate of University of Warwick

L10 FeNi (the meteoritic mineral tetrataenite) is a ferromagnetic, atomically ordered material comprising alternating layers of Fe and Ni atoms in a tetragonal crystal structure. Consisting entirely of two earth-abundant elements, and with experimental reports of a large saturation magnetistaion and impressive magnetocrystalline anisotropy, it is under scrutiny as a sustainable permanent magnet for advanced applications. However, at present there remain two fundamental questions to address regarding development of this material. The first relates to the L10 atomic disorder-order transition temperature—the temperature below which, given suitable processing, the atoms in the material will arrange themselves into this crucial tetragonal crystal structure. The second relates to the value of its magnetocrystalline anisotropy energy, defining how ‘hard’ a permanent magnet the atomically ordered phase might be. Despite a number of theoretical and experimental studies on this system, there is no clear consensus in the literature on an exact value for either of these two key quantities. In this talk I will elucidate both of these aspects using a holistic modelling approach based on density functional theory calculations of the material’s electronic structure. Crucially, the modelling approach uses the same description of the underlying electronic ‘glue’ of the material to describe both atomic ordering and magnetocrystalline anisotropy. I will present results showing how an applied magnetic field and/or mechanical strain during the annealing process can affect the atomic disorder-order transition, and also discuss the origins of the wide spread in reported values for the material’s experimentally reported uniaxial anisotropy energy. These results provide fundamental physical insight into this technologically relevant magnetic material.

Rare-earth lean and free magnets: computational modelling of fundamental properties
by Christopher Patrick of Department of Materials, University of Oxford

Removing rare-earth elements entirely from permanent magnets would be ideal from a critical materials point of view. The next-best thing would be to reduce their concentration, and this has led to much interest in the so-called “one-twelve” family of permanent magnets which only require one RE per twelve transition metal atoms. In this talk I will describe our attempts to understand these and other permanent magnets from a fundamental point of view. In particular I will discuss how titanium – required to make the material thermodynamically stable – has an adverse effect on the coercivity, through dramatically reducing the magnetocrystalline anisotropy. More generally I will discuss the challenges and opportunities associated with computational modelling of these fascinating – and complex- materials.

100% Recycled Magnets made with the HPMS Process
by Abeshaa Mahendran of Hypromag

Hypromag utilises the patented HPMS (Hydrogen Processing of Magnetic Scrap) process in order to liberate NdFeB magnet material from end of life components. Through the use of the HPMS process and recycling back to sintered magnets, there is a reduction of 98% in human toxicity and 85% of the energy used when compared to primary production. HyProMag’s current magnet manufacturing scheme uses a small addition of virgin material to ensure the retention of magnetic properties. The work presented herein explores the use of 100% secondary material for creation of magnets, for use in specific applications. Unlocking the potential for 100% recycled magnets has significant downstream benefits, while simultaneously unlocking additional opportunities in the marketplace.

The Advanced Propulsion Centre’s view on Lifecycle assessments
by Matt Shillito of Advanced Propulsion Centre UK

An insight into how the sector needs to transition its product life cycle thinking, how implementing more sustainable practices can lead to improved design, waste reduction and can help to accelerate the transition to zero emission transportation. How we can adjust our approach to product development and best utilise the outputs of LCA to maximise the benefits for the industry and the environment.

Critical raw materials – Automotive perspective
by John Reeve of FluxSys Ltd

In this talk John will outline the key critical raw materials currently used in the automotive sector, focusing mainly of the electric machines as major users. This will include ‘low power’ automotive applications such as steering and ancillary drives, as well as electrifies powertrains which are currently driving an acceleration in demand. We will review the main technologies in use so far, and some of the trends and initiatives in the automotive sector to reduce reliance on critical materials such as ‘reduced-RE’, ‘RE-free’ and ‘magnet-free’ motors, and efforts towards design for end of life and recycling

Current challenges and opportunities within the primary REE mining and secondary REE recycling sector.
by Lee Constable, of Ionic Rare Earths / Ionic Technologies

Should we be Talking about Critical Materials or Critical Solutions?
by Andrew Hine of Greenspur

Governments and companies all over the world are making 2050 Net Zero commitments to reduce the impact of climate change. The public is generally supportive of these initiatives and the need to move away from fossil fuels to reduce carbon emissions. Critical Materials, and high-performance magnets in particular, are needed by the EV and offshore wind market to deliver on ambitious Net Zero targets. However, these industries are now facing genuine scale up challenges, and their “Product Market Fit” is now being questioned by market cynics and climate change deniers. For some sceptics the products now being offered are too expensive and represent a backward step. One option is to carry on and assume that we can find new material sources or technical breakthroughs, to reduce critical materials cost and solve existing product problems. A second, and currently overlooked option, would be to assess whether existing materials and technologies could be used in different ways to develop and scale new cost competitive solutions at a much faster pace. This presentation will explore the current state of the EV and offshore wind markets, assess known product and market problems, and present some alternative solutions for consideration.