Maximum Energy Products (MGOe) 10 Maximum Energy Products (kj/m ) 3

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Clifton Matthews
6 years ago
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1 60 Maximum Energy Products (MGOe) Maximum Energy Products (kj/m ) 3

2 Guiding principles which led to the new magnets: Old Transition New Guiding principle Alnico SmCo 5 Getting high coercivity by using high anisotropy fields originated from 4f electrons SmCo 5 Sm 2 Co 17 Getting high remanence by using high saturation magnetization of Sm 2 Co 17 Sm 2 Co 17 Nd 2 Fe 14 B Getting an Fe-base magnet by extending the search for R-Fe-X ternary systems with various R (R=Rare Earth)

3 At MMM Conference, November 10, 1983

4 Map ofthe magnetic properties of the NdFeB sintered magnets and corresponding applications BH) max MGOe MRI, Speaker BH -49H XNEOMAX N NEOREC HDD, CD, DVD, MD, VTR, Digital camera, Head phone ABS sensor -40BH -39SH -38AH OAFA motor Servo motor Compressor motor -35SH -35EH Motor for robotics Generator -32EH HEV driving motor H cj koe

5 Map ofthe magnetic properties of the NdFeB sintered magnets and corresponding applications BH) max MGOe MRI, Speaker BH -46BH H HDD, CD, DVD, MD, VTR, Digital camera, Head phone ABS sensor -42VH -39SH -38VH 2000 OAFA motor Servo motor Compressor motor -35SH -35EH Motor for robotics Generator -32EH HEV driving motor H cj koe

6 Process for the NdFeB sintered magnets Raw Materials Melting Course Grinding Jet Milling Compaction Sintering Annealing Nd, Dy, Fe, B

7 Process for the NdFeB sintered magnets Raw Materials Melting Course Grinding Jet Milling Compaction Sintering Annealing Nd, Dy, Fe, B Improvements: Strip Casting Hydrogen Decrepitation Lubricant Low pressure pressing Binder High magnetic field Low oxygen process

8 NdFeB Sintered Magnets Amount of Production(t/year)

9 NdFeB Bonded Magnets Amount of Production(t/year)

12 Map ofthe magnetic properties of the NdFeB sintered magnets and corresponding applications BH) max MGOe MRI, Speaker BH -46BH -44H XNEOMAX N NEOREC HDD, CD, DVD, MD, VTR, Digital camera, Head phone ABS sensor -42VH -39SH -38VH OAFA motor Servo motor Compressor motor -35SH -35EH Motor for robotics Generator -32EH HEV driving motor H cj koe

13 VCM

14 Application of NdFeB sintered magnets (Pick-up for CD-ROM) Tracking coil Focus coil NdFeB magnet Optical pick-up Lense

15 Application of NdFeB sintered magnet (IPM compressor motor for air conditioner) Outside the house Inside the house Compressor NdFeB magnet DC motor IPM rotor

16 AirConditioner Induction motor IPM synchronous motor Efficiency isimproved by 20% statistically!

17 35km/liter!

18 Map ofthe magnetic properties of the NdFeB sintered magnets and corresponding applications BH) max MGOe MRI, Speaker BH -46BH -44H XNEOMAX N NEOREC HDD, CD, DVD, MD, VTR, Digital camera, Head phone ABS sensor -42VH -39SH -38VH OAFA motor Servo motor Compressor motor -35SH -35EH Motor for robotics Generator -32EH Strong needs HEV driving motor H cj koe

19 Composition of the NdFeB sintered magnets 50 31Nd-68Fe-1B BH) max MGOe Nature Dy 0.1 Nd 26Nd-5Dy-68Fe-1B 21Nd-10Dy-68Fe-1B H cj koe

20 Map ofthe magnetic properties of the NdFeB sintered magnets and corresponding applications BH) max MGOe MRI, Speaker BH -46BH -44H XNEOMAX N NEOREC HDD, CD, DVD, MD, VTR, Digital camera, Head phone ABS sensor -42VH -39SH -38VH OAFA motor Servo motor Compressor motor -35SH -35EH Motor for robotics Generator -32EH Hybrid car application requires this range! HEV driving motor H cj koe

21 Direction of our development 0% Dy Increasing anisotropy H cj koe BH)max MGOe

22 Pressless Process (PLP) Sintering

24 PLP

25 Coercivity of NdFeB sintered magnets (PLP Experimental data) μm17kOe H cj koe μm16.5kOe 5μm13.5kOe D1.5d Particle size dμm Grain size Dμm

26 PLP Record % Dy (Particle size=2.7μm BH) max MGOe H cj koe

30 /kg Prices of Rare Earths Nd price also soars!

31 /kg Prices of Rare Earths

32 Our goalfor PLP Net Shape Production Yield 90

33 New National Project in Japan Subject: Development of Alternative Materials for Rare Metals Rare Metals: W for toolings Dyfor NdFeB magnets In for LCD Term: Budget: 5.5BJPY (34M Members for Dy: Intermetallics Co.,Ltd. Tohoku University NationalInstitute for Material Science etc.

34 Coercivity of NdFeB sintered magnets (PLP Experimental data) μm17kOe H cj koe μm16.5kOe 5μm13.5kOe D 1.5d Particle size dμm Grain size Dμm

35 Object of the National Project % Dy Present level BH) max MGOe H cj koe

36 How to reach the object? Athorough investigation aboutthe relation between microstructure and coercivity in NdFeB magnets. Athorough investigation aboutthe mechanism of the magnetization reversal,including calculations based on the first principle. Determination of the ideal structure forthe NdFeB magnet. Determination of the process for the NdFeB magnet with the ideal structure.

37 NdFeB Magnets rescue the Earth.

38 To rescue the Earth,let s act: Al motors in allfactories NdFeB PM motors Al motors for elevators NdFeB PM motors Al motors for air conditioners NdFeB PM motors Al motors for refrigerators NdFeB PM motors Al motors for trains NdFeB PM motors Alcars HEV or EV

39 e. g. Problems? Let s overcome! Shortage of Nd, Dy? Find new mines! Cost of NdFeB magnets? Find a way for cost reduction! Cost of HEV Develop HEV with acceptable cost! (Toyota is doing.)

40 Isitimpossible to find a new magnet after the NdFeB magnet? To find a new magnet after the NdFeB magnet,a new guiding principle must be found: The guiding principle for the NdFeB magnet is useless any more.

41 We have allsorts of mystery in the coercivity ofthe NdFeB magnets. Profound and thorough researches on the coercivity of the NdFeB magnets wilgive us a new guiding principlefor a new magnet!

Rare Earth Magnets: Yesterday, Today And Tomorrow. John Ormerod Senior Technology Advisor Magnet Applications, Inc.

Rare Earth Magnets: Yesterday, Today And Tomorrow John Ormerod Senior Technology Advisor Magnet Applications, Inc. Quotes About Research If we knew what we were doing, it wouldn t be called research. -