Nd-Fe-B Magnete Eigenschaften und Anwendungen. FEMAG Tagung. 15. Oct in Würzburg. presented by. Michael Weickhmann

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1 Nd-Fe-B Magnete Eigenschaften und Anwendungen FEMAG Tagung 15. Oct in Würzburg presented by Michael Weickhmann

2 Agenda General Overview VAC Permanent magnets New Material VACODYM 8XX new motor grades.pps Corrosion resistant Grades Spray-Coatings.pps Some examples of application Application samples.pps Hot Side / Cold Side Effect at die pressing of AP Grades Cold-Side-Effect of AP Grade.pps Licence page 2

3 Magnetic Materials Rolling Process Rapid Solidification 2.5 FeCo SMC Pure Fe, 3%FeSi 2.0 C-Steels Fe Nanocrystalline 1.5 CoFeNi FeCoCr FeCoV FeMnNiTi FeNi (medium) 2.0 FeCoVCr Fe Cr Co FeNiAlTi NdFeB RE-Co FeSiAl 1.0 Powder cores 1.0 Ni-Fe Cr-, Co- Steels FeNi 80% AlNiCo MnAlC Pt Co (Permalloys) 0.5 Amorphous Co-based 1.5 Soft ferrites NdFeB bonded Cu Ni Fe 0.5 Hard ferrites Coercivity Hc /(A/cm) soft magnetic semi hard magnetic hard magnetic page 3 Remanece Br / T 2.5 Saturation magnetization Js / T Powder Route

4 types of permanent magnets 1,40 Nd-Fe-B sintered remanence B r (T) 1,20 1,00 Sm-Co sintered Sm-Co bonded 0,80 compression Nd-Fe-B anisotropic bonded Nd-Fe-B isotropic bonded injection compression 0,60 injection 0,40 sintered bonded 0,20 Ferrit 0, coercivity HcJ (ka/m) page 4

5 Production process Vacuum-Melting Casting Production-Process for Rare-Earth Permanent Magnets Crushing Milling Aligning H P P P P isostatic - Pressing H die- Sintering /Annealing Machining/ Surface-Treatment H Magnetizing H page 5

6 page 6

7 Technical Advantages NdFeB NdFeB magnets support future market requirements: Energy efficiency / energy savings Small size Low weight Less maintenance > wind mills, compressors, automotive > industrial automation and automotive > automotive > elevators and production automation Market trends: Technical solutions with permanent magnets Replacement of single magnets with magnet assemblies page 7

8 Agenda General Overview VAC Permanent magnets New Material VACODYM 8XX new motor grades.pps Corrosion resistant Grades Spray-Coatings.pps Some examples of application Application samples.pps Hot Side / Cold Side Effect at die pressing of AP Grades Cold-Side-Effect of AP Grade.pps Licence page 8

9 VACODYM AP, axial die pressed grades 1,45 VD 362/642 AP VD 510 AP VD 6XX AP VD 7XX AP VD 8XX AP 1, remanence at 20 C (T) 1,35 1,3 1, , , ,1 881 max. continuous B/µ0H = -1 1,05 60 C C C C C C 200 C coercivity at 20 C (koe) page 9

10 VACODYM TP, transvers die pressed grades 1,5 VD 362/642 TP VD 510 TP VD 6XX TP VD 7XX TP VD 8XX TP 1, remanence at 20 C (T) 1, , , , , ,15 max. continuous B/µ0H = -1 1,1 50 C 70 C 100 C 150 C C 190 C 220 C 1, coercivity at 20 C (koe) page 10

11 typical demagnetization curves of VACODYM 872 AP B/µo.H -1,0-1,5-2,0-4,0 VACODYM872AP 20 C -0,5 100 C 150 C 120 C 180 C 210 C -20 koe -18 ka/m H T kg 1,6 1,4 1,2 1,0 0,8 0,6 0,4 0,2 0,0-0,2-0,4-0,6-0, page

12 typical demagnetization curves of VACODYM 890 AP B/µo.H -1,0-1,5-2,0-4,0 VACODYM890AP 20 C -0,5 150 C 120 C 210 C 180 C 240 C -20 koe ka/m H T kg 1,6 1,4 1,2 1,0 0,8 0,6 0,4 0,2 0,0-0,2-0,4-0,6-0, page 12

13 typical irreversible losses of VACODYM 890 TP Temperatur C 250 irreversible Verluste (%) 0 VACODYM 890 TP -5 B/µ0 H = 0-0, page 13

14 corrosion stability of VACODYM in HAST (130 C, 95 % humidity) 0,1 2 ) VACODYM 6XX, 8XX Massenverlust / weight loss (mg/cm 1 VACODYM 7XX 10 VACODYM herkömmliches traditional Nd-Fe-B Auslagerungsdauer (Tage) / exposure time (days) 20 page 14

15 VD 8XX, magnetic specification Charakteristische Eigenschaften Characteristic properties Werkstoff-Sorte Kennzahl1) Remanenz Koerzitivfeldstärke Energiedichte Temperaturkoeff. Material Code1) Remanence Coercivity Energy density Br typ. Tesla kg HcB typ. ka/m koe temperature coeff C C TK(Br) TK(HcJ) TK(Br) TK(HcJ) typ. typ. typ. typ. %/ C %/ C %/ C %/ C Br min. Tesla kg HcB min. ka/m koe HcJ typ. ka/m koe HcJ min. ka/m koe (BH)max typ. kj/m3 MGOe (BH)max min. kj/m3 MGOe VACODYM 863 TP 1,29 1, /200 VACODYM 863 AP 250/200 VACODYM 872 TP 265/223 VACODYM 872 AP 235/223 VACODYM 890 TP 240/263 VACODYM 890 AP 210/263 12,9 1,21 12,1 1,25 12,5 1,17 11,7 1,19 11,9 1,11 11,1 12,5 1,17 11,7 1,21 12,1 1,13 11,3 1,15 11,5 1,07 10,7 12, , , , , ,6 11, , , , , , ,100-0,56-0,110-0,51-0,100-0,56-0,110-0,51-0,095-0,53-0,105-0,49-0,095-0,53-0,105-0,49-0,09-0,50-0,1-0,46-0,09-0,50-0,1-0,46 page 15

16 Agenda General Overview VAC Permanent magnets New Material VACODYM 8XX new motor grades.pps Corrosion resistant Grades Spray-Coatings.pps Some examples of application Application samples.pps Hot Side / Cold Side Effect at die pressing of AP Grades Cold-Side-Effect of AP Grade.pps Licence page 16

17 Segmented Magnet Systems Applications: - ship motors - motors for buses - linear motors - hybrid cars - generators page 17

18 VACCOAT or Product Description - Epoxy based heat curing spray coating - Excellent corrosion protection for VACODYM or VACOMAX - Resistant against many chemicals and solvents - Resistant in humid environment - Stable in coolants - High temperature resistant - Good chip and abrasion resistance - Good edge protection page 18

19 VACCOAT 10047(1) or 20011(2) - Physical Properties - Layer thickness: > 10 µm (typical µm; 5 40 µm possible in one coating step) - Colour: satin-yellow(1) black (2) (other colours possible (2) ) - Magnetic behaviour: nonmagnetic - Electrical insulation (specific resistance > 1012 Ohm.cm) - Pencil hardness: >/= 4H - Operating temperature range: -73 to 180 C peak - Cross hatch according to ASTM D 3359: 4-5 DIN 53151: 0 1 page 19

20 VACCOAT Functional Properties: Physical Properties - Coating thickness: > 5 µm (typical µm) - Colour: metallic yellow, satin finish - Electrical conductivity: non-conducting - Magnetic behaviour: nonmagnetic -Solvent resistance MIBK -test: > 30 x (MIBK = methylisobutylketone) Environmental resistance (on VACODYM 6XX grade) - 85 C / 85% rel. Humidity: > 1000 h - HAST-Test (130 C / 2.7 bar / 100% humidity): > 72 h - Pencil hardness: > 4H (typical 6-8H) - Temperature resistance: 180 C (continuous operation); 200 C (peak) page 20

21 DM Coating VACCOAT VACODYM 677 Magnets with Al Spray Coating VACCOAT Segmented magnets have been glued After 500 h salt spray test and coated with VACCOAT After 12 d pressure cooker test (130 C / 2,7 bar / 100%!! humidity) Homogeneous coating thickness even around edges page 21

22 Edge Protection VACCOAT barrel painting process page 22

23 Agenda General Overview VAC Permanent magnets New Material VACODYM 8XX new motor grades.pps Corrosion resistant Grades Spray-Coatings.pps Some examples of application Application samples.pps Hot Side / Cold Side Effect at die pressing of AP Grades Cold-Side-Effect of AP Grade.pps Licence page 23

24 Application Motors VACODYM high performance permanent magnets Linear motors Precise high speed positioning - production automation e.g. in semiconductor industry Servo motors High dynamics, high efficiency, energy saving - production automation e.g. drives in robots page 24

25 Application Ship motors NdFeB magnets NdFeB magnets SSP Propulsor * Power ranges up to 30 MW page 25

26 Application Windgenerator Generator ring appr. 80 big Magnets placed in the inner ring of the generator page 26

27 Other applications Medical MRI assemblies special motors (dental, surgery, ) Scientific / Measurement Wiggler / Undulators NMR Mass Spectrometers Precision Balances Miscellaneous Bearings page 27

DM - Application focus Automotive Sensors traditional + Double Clutch

Auxiliary Motors water pump, fuel pump, Brake by wire Ignition Coils

Stability of VACODYM 6xx Low Cost Barrel Coating VACCOAT 10047 or 20011

28 DM - Application focus Automotive Sensors traditional + Double Clutch Gearbox control EPS Electric Power Steering Hybrid Motor Electrical Auxiliary Motors water pump, fuel pump, Brake by wire Ignition Coils Unique Selling Points New motor grades VACODYM 7xx and 8xx Corrosion Stability of VACODYM 6xx Low Cost Barrel Coating VACCOAT or excellent salt spray and corrosive gas resistance Only Highest volume producer in Europe page 28

29 Projects for E-Machines for Trams or Hybrid Commuter trains Concept of Tram PM- Machine 16 per train PM Machine for High speed train 1 MW 305 km/h PM E Machine for Tram/Train page 29

30 Agenda General Overview VAC Permanent magnets New Material VACODYM 8XX new motor grades.pps Corrosion resistant Grades Spray-Coatings.pps Some examples of application Application samples.pps Hot Side / Cold Side Effect at die pressing of AP Grades Cold-Side-Effect of AP Grade.pps Licence page 30

31 AP Grade versus TP Grade - What is the difference between the AP grade and the TP grade? - How can we model the Cold Side / Hot Side effect with AP grade using Finite Element Analysis adequately? - Why do we suggest AP grade instead of TP grade? - Let us look deeper into the problem of magnetisation of embedded magnets! - How does AP grade influence the flux density in the air gap? page 31

32 AP Grade versus TP Grade Dimple to mark the cold Side punches die support filling plate Magnet 2 coil Easy Axis coil 3 page 32

33 CIP (Rubber Isostatic Pressing) TP 51 (Transverse Field Die Pressing of Contour Blocks) 7% 5% 53 (Cold Isostatic Pressing) 49 8% 8% AP (Axial Field Die Pressing of single parts and blocks) 43 VACODYM 722 TP (Transverse Field Die Pressing of Cubic Blocks) Normal-Qualität orientation degree [%] HR RIP max. energy density [MGOe] low medium high final machining expenditure page 33

Model of AP Grade with Hot and Cold side AP Cold / Hot Side an Quader 26x10x4 mm VD 890 AP @ 10 mm Abstand 0,07 0,06 Flußdichte [T] 0,05 0,04 Cold Side Hot Side 0,03 0,02 0,01 0,00 0,00 1,81 3,62

34 Model of AP Grade with Hot and Cold side AP Cold / Hot Side an Quader 26x10x4 mm VD mm Abstand 0,07 0,06 Flußdichte [T] 0,05 0,04 Cold Side Hot Side 0,03 0,02 0,01 0,00 0,00 1,81 3,62 5,44 7,25 9,06 10,87 12,68 14,50 16,31 18,12 19,93 21,74 23,56 25,37 entlang Abmessung [mm] Hot Side Cold Side Magnets AP grade segmented in 6 sub-magnets, where the lower sub-block Cold Side) are set with an inclination of magnetic orientation of +20 and 20 respectively. The Flux density is calculated at the upper and the lower side at a distance of roughly the width of the magnets, leading to a difference of flux density of appr. 14 % Note: Cold-Side is marked with a dimple page 34

35 Diametrical Grade versus AP Grade Diametrical / Parallel Orientation 0.03 AP grade Orientation 0.03 B.n, Tesla B.n, Tesla Hot Side Leng th, mm Leng th, mm Comparing the Flux density at the upper and lower side of the magnets in air at a distance of appr. the width of the magnet shows a difference of Flux density depending on the parallel, diametrical orientation versus the typical AP grade orientation. m m, ht g n e L m m, ht g n e L als e T, n. B Cold Side als e T, n. B page 35

36 Advantages of AP Grade vs. TP Grade - AP grade is manufactured as single magnets on fast running machines / presses - Material yield is very high i.e. very little waste during grinding - Manufacturing cost are low - Consistency of magnetic values Br is very good within a batch - Low variance distribution of Br within a batch and from batch to batch - TP grade is manufactured as blocks on slow running machines / presses which need to be sliced and ground after sintering - Material yield is very low i.e. very high waste during cutting and grinding - Manufacturing cost are high - Consistency of magnetic values Br may vary sporadically - High and variance distribution of Br within a batch and from batch to batch page 36

37 AP Grade versus TP Grade - Let us look deeper into the problem of magnetisation of embedded magnets! -The magnetic field imposed onto the embedded magnets co-aligns with the intrinsic orientation of the magnets caused by the Hot / Cold side effect during die pressing. page 37

38 Magnetisation of embedded tangential magnets Hot Side Cold Side Tangential arrangement of embedded magnets in a rotor. The field of magnetisation diverges at the lower left and right hand side of the magnets. If the intrinsic orientation of the magnet co-aligns with the outer H field, the saturation can be achieved at every part of the magnet, if the Hot Side is placed towards the air gap. The H field should be at 2500 ka/m to saturate the magnet. page 38

39 H field at upper and lower side of magnet Normal component of H field vector 3.4e+006 Absolute value of H field vector 4e+006 H.n, A mp/m 3.3e e+006 H, A mp/m 3.5e e+006 3e e+006 3e+006 Upper Side of Magnet 2.8e e e e e e+006 2e Leng th, mm Leng th, mm 2.6e e +006 H.n, A mp /m 2.5e +006 H, A mp /m 3e e e e e +006 Lower Side of Magnet 2.6e e e e e e e e e Len g th, mm Len g th, mm Field distribution at upper (Hot Side) and lower side of magnet, when magnetising embedded tangential magnets. Observe the orientation of H field lines. page 39

40 Advantages of AP Grade vs. TP Grade page 40

41 Field distribution of embedded tangential magnets Hot Side Cold Side Tangential arrangement of magnetised embedded magnets in a rotor. The field of magnetisation diverges at the lower left and right hand side of the magnets. If the intrinsic orientation of the magnet co-aligns with the outer H field, the saturation can be achieved at every part of the magnet. Compare the flux lines with the field distribution of the magnetisation field 2 slide before. page 41

42 AP Grade versus TP Grade - Let us look deeper into the problem of magnetisation of embedded magnets! - How does AP grade influence the flux density in the air gap? -The air gap flux density at a not sloted stator shows a significant increase almost comparable with TP grade. page 42

43 AP Grade with parallel, diametrical orientation page 43

44 AP Grade with Hot side / Cold Side effect Hot Side 20 inclination Cold Side 20 inclination page 44

45 Flux density in Air gap diametrical Orientation vs. Cold / Hot Side effect. Luftspaltinduktion Stator nicht genutet VACODYM 890 diametral Ausrichtung vs. AP Ausrichtung Air gap flux density at a not slotted stator VACODYM 890 diametrical orientation vs. AP orientation 0,80 0,60 Flußdicht [T] Flux density [T] 0,40 0,20 AP aproximiert 6 Segmente 0,00 0,00 8,03 16,07 24,10 32,13 40,17 48,20 56,23 64,26 72,30 80,33 88,36 96,40 104,43 112,46 AP paral. diametral -0,20-0,40-0,60-0,80 Umfang [mm] Circumference [mm] Flux density in the air gap comparing parallel diametrical orientation vs. Hot / Cold Side effect of AP Grade ( this can be illustrated by using a stator without slots ). page 45

46 AP Grade versus TP Grade Air gap Flux density page 46

47 AP Grade versus TP Grade Air gap Flux density Luftspaltinduktion Stator nicht genutet VACODYM 890 diametral Ausrichtung vs. AP Ausrichtung Air gap flux density at a not slotted stator VACODYM 890 diametrical orientation vs. AP orientation 0,80 0,60 0,40 Flußdicht [T] Flux density [T] 0,20 AP aproximiert 6 Segmente 0,00 AP paral. diametral 0,00 8,03 16,07 24,10 32,13 40,17 48,20 56,23 64,26 72,30 80,33 88,36 96,40 104,43 112,46 TP qualität -0,20-0,40-0,60-0,80 Umfang [mm] Circumference [mm] Flux density in the air gap comparing parallel diametrical orientation vs. Hot Cold Side effect of AP Grade and TP Grade ( this can be illustrated by using a stator without slots ). page 47

48 License Situation License situation sintered NdFeB magnets: NEOMAX license valid until manufacturers in Europe ((VAC, Neorem)*, Magnetfabrik Schramberg) 3 manufacturers in Japan (NEOMAX, Shin Etsu, TDK) 5 licensed manufacturers in China (not free for Japanese Market) Market in Europe only free for NEOMAX, European licensees, and Chinese licensees Market in Japan only free for Japanese licensees Rest of the world is free for all licensees * (VAC took over Neorem in April 2007) page 48

49 I thank you for your undivided attention! page 49

50 Rare Earth material costs page 50

Industrial developmentof materials forsustainable development(magnets + magneto-caloric materials) M. Katter

Industrial developmentof materials forsustainable development(magnets + magneto-caloric materials) M. Katter 11.09.08 PowderMetallurgy the industrialproduction route forhighly efficient magnetic parts