INNOVATIVE RESEARCH AND PRODUCTS, INC.

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1 INNOVATIVE RESEARCH AND PRODUCTS, INC. ET-121 PERMANENT MAGNETS - TYPES, APPLICATIONS, NEW DEVELOPMENTS, INDUSTRY STRUCTURE AND GLOBAL MARKETS Babu Lal Gupta Project Analyst Dr. Thomas Abraham Project Supervisor INNOVATIVE RESEARCH AND PRODUCTS, INC. P.O. Box Stamford, CT Phone: (203) Web: innoresearch@innoresearch.net i

2 ABOUT irap Innovative Research and Products (irap) Inc. conducts market research and industry analysis in new-generation technologies and products. Areas covered include advanced materials, nanotechnology and nanomaterials, processing technologies and products, advanced ceramics, metals and alloys, high-performance coatings, automotive components, aircraft and aerospace materials, electronic devices, photonic components, membranes, plastics, pharmaceutical products and biotechnology. CUSTOM ANALYSIS irap will be happy to talk to you about your market research needs if you need to expand on the current market survey to cover a new product or technology. We are confident that we will meet your expectations and provide you the most accurate industry and market analysis. Send us an of your market research and industry analysis objectives and we will provide you a FREE quote. TERMS OF PURCHASE By purchasing this report, the purchaser is bound to the following conditions: The report may only be used by the group or the division which bought this report. The report may not be copied and sent to other groups or divisions in the same company or other companies. Other than for internal use, any quotes from this report may be made only with written permission from the publisher. DISCLAIMER irap has compiled information in this report as accurately as possible at the time of its publication. irap cautions that any information contained in this report should not be considered as a policy guide or endorsement of any company, technology or product. irap takes no responsibility for any losses or damages that might result from reliance on these materials. Copyright 2014 by Innovative Research and Products, Inc., Stamford, CT 06905, USA. Reproduction of any passage, table or figure herein is strictly forbidden without permission from irap. March 2014 ii

3 TABLE OF CONTENTS INTRODUCTION... 1 STUDY GOALS AND OBJECTIVES... 1 CONTRIBUTIONS OF THE STUDY... 2 FORMAT AND SCOPE... 3 METHODOLOGY AND INFORMATION SOURCES... 3 WHO SHOULD SUBSCRIBE... 4 AUTHOR S CREDENTIALS... 4 EXECUTIVE SUMMARY... 6 SUMMARY TABLE- GLOBAL MARKET FOR PERMANENT MAGNETS... 7 SUMMARY FIGURE-GLOBAL MARKET FOR PERMANENT MAGNET SEGMENTS IN 2013 AND INDUSTRY OVERVIEW... 9 INDUSTRY STRUCTURE MARKET OVERVIEW CHINA MARKET U.S. MARKET EUROPE JAPAN OTHER COUNTRIES TECHNOLOGY AND APPLICATIONS PERMANENT MAGNETIC MATERIALS TABLE 1 - NOMINAL COMPOSITIONS, CURIE TEMPERATURES, AND MAGNETIC ORIENTATIONS OF SELECTED PERMANENT MAGNET MATERIALS TABLE 1-(CONTINUED) SUMMARY OF PROPERTIES TABLE 2-SUMMARY OF RANGE OF PROPERTIES OF PERMANENT MAGNET MATERIALS TABLE 3-NOMINAL MAGNETIC PROPERTIES OF SELECTED PERMANENT MAGNET MATERIALS TABLE 4-NOMINAL MECHANICAL AND PHYSICAL PROPERTIES OF SELECTED PERMANENT MAGNET MATERIALS iii

4 TABLE 5-TERMS/DEFINITIONS RELATED TO PERMANENT MAGNETS TABLE 5- CONTINUED 24 TABLE 5-CONTINUED.25 TABLE 5- CONTINUED 26 TABLE 5- CONTINUED 27 TABLE 5- CONTINUED 28 TABLE 5- CONTINUED 29 TABLE 5- CONTINUED 30 CERAMIC HARD FERRITE MAGNETS MATERIAL TYPES MANUFACTURING PROCESSES PROPERTIES PHYSICAL AND MECHANICAL PROPERTIES ELECTRICAL AND MAGNETIC PROPERTIES TABLE 6-MAGNETIC PROPERTIES OF CHINESE CERAMIC MAGNETS TABLE 7-EQUIVALENT MAGNETIC PROPERTIES OF U.S. VS. CHINESE HARD FERRITE CERAMIC MAGNETS APPLICATIONS OF HARD FERRITES APPLICATIONS OF HARD FERRITES (CONTINUED).35 APPLICATIONS OF HARD FERRITES (CONTINUED).36 TABLE 8-APPLICATIONS OF HITACHI S RADIALLY ORIENTED RING CERAMIC MAGNETS PRICING OF FERRITE MAGNETS TABLE 9-PRICING OF COMMERCIALLY AVAILABLE FERRITE PRODUCTS INDUSTRY STRUCTURE LIST OF MANUFACTURERS MARKET SHARES OF COMPANIES TABLE 10-MARKET SHARE OF TOP MANUFACTURERS OF FERRITE MAGNETS IN GLOBAL MARKET SIZE TABLE 11-GLOBAL MARKET OF HARD FERRITE PERMANENT MAGNETS, NEODYMIUM-IRON-BORON (ND-FE-B) RARE EARTH MAGNETS MANUFACTURING PROCESSES iv

5 MANUFACTURING PROCESSES(CONTINUED) 42 FIGURE 1-NEODYMIUM-IRON-BORON MAGNET PRODUCTION CYCLE 43 PROPERTIES, COMPOSITIONS AND GRADES TABLE 12-MMPA DESIGNATIONS FOR RARE EARTH IRON-BORON MAGNETS TABLE 13-MAGNETIC CHARACTERISTICS OF TDK S NEOREC NDFEB MAGNETS APPLICATIONS TABLE 14-GLOBAL MARKET SHARE BY WEIGHT FOR NEODYMIUM- IRON-BORON MAGNETS BY APPLICATION AUTOMOTIVE INDUSTRY HDDS, CDS, DVDS ELECTRIC BICYCLES TRANSDUCERS AND LOUDSPEAKERS MAGNETIC SEPARATION MRIS TORQUE-COUPLED DRIVES SENSORS HYSTERESIS CLUTHES GENERATORS ENERGY STORAGE SYSTEMS WIND POWER GENERATORS FIGURE CONVENTIONAL AND DIRECT DRIVE WIND TURBINES AIR CONDITIONING COMPRESSORS AND FANS HYBRID AND ELECTRIC DRIVES OTHER USES PRICE PATTERN OF NEODYMIUM-IRON-BORON MAGNETS TABLE 15-PRICE PATTERN OF COMMERCIALLY AVAILABLE NEODYMIUM-IRON-BORON PERMANENT MAGNETS PRODUCTS ISSUES AND CHALLENGES IN USE OF LIGHT EARTH METALS AND HEAVY EARTH METALS (USE OF DYSPROSIUM IN NEODYMIUM-IRON- BORON PERMANENT MAGNETS) HEAVY EARTH METALS (USE OF DYSPROSIUM IN NEODYMIUM-IRON- BORON PERMANENT MAGNETS) (CONTINUED).54 NED-FE-B PERMANENT MAGNET ISSUES AN OVERVIEW NED-FE-B PERMANENT MAGNET ISSUES AN OVERVIEW (CONTINUED)..55 v

6 NED-FE-B PERMANENT MAGNET ISSUES AN OVERVIEW (CONTINUED)..56 INDUSTRY STRUCTURE LIST OF MANUFACTURERS TABLE 16-GLOBAL MANUFACTURERS OF NDFEB MAGNETS GLOBAL MARKET SIZE TABLE 17-GLOBAL MARKET FOR NEO PERMANENT MAGNETS, 2013 AND MARKET SIZE BY APPLICATION FOR NEODYMIUM-IRON-BORON PERMANENT MAGNETS TABLE 18-GLOBAL MARKET FOR NEODYMIUM-IRON-BORON MAGNETS BY APPLICATION, 2013 AND PERMANENT MAGNETS ( CONTINUED) 61 PERMANENT MAGNETS ( CONTINUED) 62 RARE-EARTH COBALT MAGNETS MATERIALS AND TYPES TABLE 19-RARE EARTH MAGNET DESIGNATIONS TABLE 20-NOMINAL COMPOSITION, CURIE TEMPERATURE AND MAGNETIC ORIENTATION OF COMMERCIAL RARE-EARTH COBALT MAGNETS RARE-EARTH COBALT RARE-EARTH 2 TRANSITION METAL 17 GROUP MANUFACTURING PROCESSES PROPERTIES PHYSICAL AND MECHANICAL PROPERTIES TABLE 21-NOMINAL PHYSICAL AND MECHANICAL PROPERTIES OF RE MAGNETS MAGNETIC PROPERTIES TABLE 22-NOMINAL MAGNETIC PROPERTIES OF RARE EARTH/COBALT MAGNETS TABLE 23-MAGNETIC PROPERTIES OF SOME COMMERCIALLY AVAILABLE RARE EARTH COBALT MAGNETS APPLICATIONS PRICE PATTERN OF SAMARIUM-COBALT PERMANENT MAGNETS INDUSTRY STRUCTURE LIST OF MANUFACTURERS vi

7 TABLE 24-GLOBAL MANUFACTURERS OF SAMARIUM-COBALT MAGNETS GLOBAL MARKET TABLE 25-GLOBAL MARKET OF SAMARIUM-COBALT PERMANENT MAGNETS ALNICO PERMANENT MAGNETS MATERIALS AND TYPES TABLE 26-ALNICO MAGNET DESIGNATIONS AVAILABLE SHAPES AND SIZES PROPERTIES CAST ALNICOS TABLE 27-NOMINAL COMPOSITION, CURIE TEMPERATURE AND MAGNETIC ORIENTATION OF CAST ALNICOS TABLE 28-MAGNETIC PROPERTIES OF CAST ALNICO MAGNETS TABLE 29-NOMINAL PHYSICAL AND MECHANICAL PROPERTIES OF CAST ALNICO MAGNETS SINTERED ALNICOS TABLE 30-NOMINAL COMPOSITION, CURIE TEMPERATURE AND MAGNETIC ORIENTATION OF SINTERED ALNICOS TABLE 31-MAGNETIC PROPERTIES OF SINTERED ALNICO MAGNETS TABLE 32-NOMINAL PHYSICAL AND MECHANICAL PROPERTIES OF SINTERED ALNICO MAGNETS MANUFACTURING PROCESSES CAST ALNICOS SINTERED ALNICOS HEAT TREATMENT FINISHING APPLICATIONS PRICE PATTERN OF ALNICO PERMANENT MAGNETS TABLE 33-PRICE PATTERN OF COMMERCIALLY AVAILABLE ALNICO PRODUCTS INDUSTRY STRUCTURE LIST OF MANUFACTURERS TABLE 34-LEADING GLOBAL MANUFACTURERS OF ALNICO MAGNETS GLOBAL MARKET SIZE TABLE 35-GLOBAL MARKETS OF ALNICO PERMANENT MAGNETS vii

8 BONDED AND FLEXIBLE PERMANENT MAGNETS MATERIALS AND TYPES BONDING MATERIALS COMPOSITIONS AND GRADES OF BONDED MAGNETS TABLE 36-POWDER SPECIFICATIONS OF BONDED FERRITE MANUFACTURING PROCESSES PRODUCING BONDED MAGNETS VIA EXTRUSION FIGURE 3-BONDED MAGNET PRODUCTION VIA EXTRUSION PROCESS PRODUCING BONDED MAGNETS VIA INJECTION MOLDING FIGURE 4-BONDED MAGNET PRODUCTION VIA INJECTION MOLDING PROCESS PRODUCING BONDED MAGNETS VIA COMPRESSION FIGURE 5-BONDED MAGNET PRODUCTION VIA COMPRESSION MOLDING PROCESS CALENDERING AND PRODUCING FLEXIBLE SHEET FIGURE 6-BONDED MAGNET PRODUCTION VIA CALENDERING PROCESS APPLICATIONS TABLE 37-APPLICATIONS FOR TYTEK INDUSTRIES MAGNETS TABLE 38 APPLICATIONS FOR TDK S COMPOSITE MAGNETS PRICE PATTERN OF BONDED MAGNETS TABLE 39-AVERAGE PRICES OF FERRITE, SMCO AND NDFEB BONDED MAGNETS INDUSTRY STRUCTURE MAJOR MANUFACTURERS TABLE 40-LEADING MANUFACTURERS OF BONDED MAGNETS IN CHINA, EUROPE, JAPAN, THE U.S., AND THE REST OF THE WORLD GLOBAL MARKET TABLE 41-GLOBAL MARKET FOR PERMANENT BONDED MAGNETS FIGURE 7-GLOBAL MARKET FOR PERMANENT BONDED MAGNETS OTHER MAGNETS ELONGATED SINGLE DOMAIN (ESD) MAGNETS IRON-CHROMIUM-COBALT MAGNET ALLOYS MANUFACTURING PROPERTIES TABLE 42-MAGNETIC PROPERTIES OF IRON-CHROMIUM-COBALT MAGNETS viii

9 TABLE 43-MAGNETIC PROPERTIES OF HITACHI IRON-CHROMIUM- COBALT MAGNETS APPLICATIONS MAGNET ALLOYS REMALLOY TABLE 44-PHYSICAL AND MECHANICAL PROPERTIES OF REMALLOY CUNIFE TABLE 45-PHYSICAL AND MECHANICAL PROPERTIES OF CUNIFE CUNICO TABLE 46-PHYSICAL AND MECHANICAL PROPERTIES OF CUNICO VICALLOY TABLE 47-PHYSICAL AND MECHANICAL PROPERTIES OF VICALLOY TABLE 48-NOMINAL COMPOSITIONS, CURIE TEMPERATURES AND MAGNETIC ORIENTATION OF MAGNET ALLOYS TABLE 49-NOMINAL MAGNETIC PROPERTIES OF MAGNET ALLOYS MAGNET STEELS TABLE 50-NOMINAL COMPOSITIONS, CURIE TEMPERATURES AND MAGNETIC ORIENTATION OF MAGNET STEELS FABRICATION PHYSICAL AND MECHANICAL PROPERTIES MAGNETIC PROPERTIES TABLE 51-NOMINAL MAGNETIC PROPERTIES OF MAGNET STEELS APPLICATIONS PLATINUM COBALT PHYSICAL AND MECHANICAL PROPERTIES TABLE 52-NOMINAL MECHANICAL PROPERTIES OF PT-CO MAGNETS MAGNETIC PROPERTIES TABLE 53-MAGNETIC PROPERTIES OF PT-CO MAGNETS APPLICATIONS MISCELLANEOUS PERMANENT MAGNET MATERIALS TABLE 54-MAGNETIC PROPERTIES OF MISCELLANEOUS PERMANENT MAGNET MATERIALS ix

10 NEW MAGNETIC MATERIALS UNDER DEVELOPMENT TABLE 55-RARE EARTH FREE NEW MAGNETIC MATERIAL RESEARCH TABLE 55-RARE EARTH FREE NEW MAGNETIC MATERIAL RESEARCH (CONTINUED) TABLE 55-RARE EARTH FREE NEW MAGNETIC MATERIAL RESEARCH (CONTINUED) INDUSTRY STRUCTURE GLOBAL MANUFACTURERS GLOBAL MANUFACTURERS (CONTINUED) ADDITIONAL MARKET PARTICIPANTS DISTRIBUTORS AND FABRICATORS TABLE 56-GLOBAL DISTRIBUTORS AND FABRICATORS OF HARD FERRITE, ALNICO AND BONDED MAGNETS TABLE 57-GLOBAL DISTRIBUTORS AND FABRICATORS OF NDFEB MAGNETS TABLE 58-GLOBAL DISTRIBUTORS AND FABRICATORS OF SM-CO MAGNETS COMPETITION AND MARKET TRENDS TABLE 59-ACQUISITIONS, MERGERS, EXPANSIONS AND NEW RESEARCH FUNDING IN COMPANIES MANUFACTURING PERMANENT MAGNETS, 2009 TO JANUARY TABLE 59-ACQUISITIONS, MERGERS, EXPANSIONS AND NEW RESEARCH FUNDING IN COMPANIES MANUFACTURING PERMANENT MAGNETS, 2009 TO JANUARY 2013 (CONTINUED) TABLE 59-ACQUISITIONS, MERGERS, EXPANSIONS AND NEW RESEARCH FUNDING IN COMPANIES MANUFACTURING PERMANENT MAGNETS, 2009 TO JANUARY 2013 (CONTINUED) TABLE 59-ACQUISITIONS, MERGERS, EXPANSIONS AND NEW RESEARCH FUNDING IN COMPANIES MANUFACTURING PERMANENT MAGNETS, 2009 TO JANUARY 2013 (CONTINUED) END USERS OF PERMANENT MAGNETS TABLE 60-APPLICATIONS AND MAJOR END USERS OF PERMANENT MAGNETS IN THE U.S., EUROPE AND JAPAN TABLE 61-CONTACT DETAILS FOR SOME SELECT END USERS OF PERMANENT MAGNETS IN THE U.S., EUROPE AND ASIA x

11 TABLE 61-CONTACT DETAILS FOR SOME SELECT END USERS OF PERMANENT MAGNETS IN THE U.S., EUROPE AND ASIA (CONTINUED) MARKET SIZE AND SHARE TABLE 62-GLOBAL MARKETS FOR PERMANENT MAGNETS FIGURE 8-GLOBAL MARKET SHARE BY TYPE OF PERMANENT MAGNET MARKET SIZE BY REGION TABLE 63-GLOBAL OUTPUT OF PERMANENT MAGNETS BY REGION IN TABLE 64-GLOBAL OUTPUT OF PERMANENT MAGNETS BY REGION IN FIGURE 9-MAGNET PRODUCTION BY REGION PATENTS AND PATENT ANALYSIS PATENTS RELATED TO FERRITE PERMANENT MAGNETS NON-AGEING PERMANENT MAGNET FROM AN ALLOY POWDER AND METHOD FOR THE PRODUCTION THEREOF METHOD OF MANUFACTURING ROTOR MAGNET FOR MICRO ROTARY ELECTRIC MACHINE HIGH SPEED INTERNAL PERMANENT MAGNET MACHINE AND METHOD OF MANUFACTURING THE SAME FERRITE MATERIAL AND METHOD FOR PRODUCING FERRITE MATERIAL SOFT MAGNETIC RIBBON, MAGNETIC CORE, MAGNETIC PART AND PROCESS FOR PRODUCING SOFT MAGNETIC RIBBON MAGNET USING BINDING AGENT AND METHOD OF MANUFACTURING THE SAME FERRITE MATERIAL PERMANENT MAGNET FOR MOTOR, MOTOR HOUSING, AND MOTOR DEVICE PERMANENT MAGNET ROTATOR AND MOTOR USING THE SAME METHOD FOR PREPARING RADIALLY ANISOTROPIC MAGNET MAGNETIC ALLOY MATERIAL AND METHOD OF MAKING THE MAGNETIC ALLOY MATERIAL PERMANENT MAGNET FOR PARTICLE BEAM ACCELERATOR AND MAGNETIC FIELD GENERATOR xi

12 PATENTS RELATED TO NEODYMIUM-IRON-BORON PERMANENT MAGNETS R-FE-B RARE-EARTH SINTERED MAGNET AND PROCESS FOR PRODUCING THE SAME RARE EARTH MAGNET AND METHOD FOR PRODUCING SAME R-FE-B POROUS MAGNET AND METHOD FOR PRODUCING THE SAME METHOD FOR PREPARING RARE EARTH PERMANENT MAGNET MATERIAL METHOD FOR PREPARING RARE EARTH PERMANENT MAGNET MATERIAL RARE EARTH ALLOY BINDERLESS MAGNET AND METHOD FOR MANUFACTURE THEREOF RARE EARTH ELEMENT-IRON-BORON ALLOY, AND MAGNETICALLY ANISOTROPIC PERMANENT MAGNET POWDER AND METHOD FOR PRODUCTION THEREOF METHOD FOR PREPARING RARE EARTH PERMANENT MAGNET RARE EARTH MAGNET AND METHOD FOR PRODUCTION THEREOF. 145 IRON-BASED RARE-EARTH NANOCOMPOSITE MAGNET AND METHOD FOR PRODUCING THE MAGNET METHOD FOR PRODUCING RARE EARTH METAL-BASED PERMANENT MAGNET HAVING COPPER PLATING FILM ON THE SURFACE THEREOF RARE EARTH MAGNET AND METHOD FOR PRODUCING SAME PROCESS FOR PRODUCING, THROUGH STRIP CASTING, RAW ALLOY FOR NANOCOMPOSITE TYPE PERMANENT MAGNET METHOD FOR PRODUCING NANOCOMPOSITE MAGNET USING ATOMIZING METHOD FUNCTIONALLY GRADED RARE EARTH PERMANENT MAGNET FUNCTIONALLY GRADED RARE EARTH PERMANENT MAGNET RARE EARTH PERMANENT MAGNET PATENTS RELATED TO BONDED AND FLEXIBLE PERMANENT MAGNETS RARE EARTH BONDED MAGNET R-FE-B RARE EARTH SINTERED MAGNET AND METHOD FOR PRODUCING SAME R-FE-B TYPE RARE EARTH SINTERED MAGNET AND PROCESS FOR PRODUCTION OF THE SAME xii

13 RARE EARTH SINTERED MAGNET AND METHOD FOR PRODUCING SAME R-T-B-TYPE SINTERED MAGNET AND METHOD FOR PRODUCTION THEREOF ALLOY FOR SINTERED R-T-B-M MAGNET AND METHOD FOR PRODUCING SAME FERRITE POWDERS FOR BONDED MAGNET, PROCESS FOR THE PRODUCTION OF THE POWDERS, AND BONDED MAGNET MADE BY USING THE SAME ANISOTROPIC RARE EARTH-IRON BASED RESIN BONDED MAGNET 153 ROTATING MACHINE, BONDED MAGNET, MAGNET ROLL, AND METHOD FOR PRODUCING SINTERED FERRITE MAGNET FERRITE MAGNET POWDER, SINTERED MAGNET, BOND MAGNET, AND MAGNETIC RECORDING MEDIUM PROCESS FOR PRODUCING SELF-ASSEMBLED RARE EARTH-IRON BONDED MAGNET AND MOTOR UTILIZING THE SAME SINTERED R-FE-B PERMANENT MAGNET AND ITS PRODUCTION METHOD YOKE-INTEGRATED BONDED MAGNET AND MAGNET ROTATOR FOR MOTOR USING THE SAME ANISOTROPIC RARE EARTH BONDED MAGNET HAVING SELF- ORGANIZED NETWORK BOUNDARY PHASE AND PERMANENT MAGNET MOTOR UTILIZING THE SAME OXIDE MAGNETIC MATERIAL AND SINTERED MAGNET OXIDE-TYPE, MAGNETIC MATERIAL AND ITS PRODUCTION METHOD, AND SINTERED FERRITE MAGNET AND ITS PRODUCTION METHOD R-T-B BASED SINTERED MAGNET SINTERED R-FE-B PERMANENT MAGNET AND ITS PRODUCTION METHOD YOKE-INTEGRATED BONDED MAGNET AND MAGNET ROTATOR FOR MOTOR USING THE SAME ANISOTROPIC RARE EARTH BONDED MAGNET HAVING SELF- ORGANIZED NETWORK BOUNDARY PHASE AND PERMANENT MAGNET MOTOR UTILIZING THE SAME BOND MAGNET FOR DIRECT CURRENT REACTOR AND DIRECT CURRENT REACTOR xiii

14 ANISOTROPIC BONDED MAGNET FOR USE IN A 4-POLE MOTOR, A MOTOR EMPLOYING THAT MAGNET, AND AN ALIGNMENT PROCESS APPARATUS FOR THE ANISOTROPIC BONDED MAGNET FOR USE IN A 4-POLE MOTOR FERRITE MAGNETIC MATERIAL AND FERRITE SINTERED MAGNET METHODS FOR PRODUCING RAW MATERIAL ALLOY FOR RARE EARTH MAGNET, POWDER AND SINTERED MAGNET METHODS FOR PRODUCING RAW MATERIAL ALLOY FOR RARE EARTH MAGNET, POWDER AND SINTERED MAGNET ANISOTROPIC BOND MAGNET FOR FOUR-MAGNETIC-POLE MOTOR, MOTOR USING THE SAME, DEVICE FOR ORIENTATION PROCESSING OF ANISOTROPIC BOND MAGNET FOR FOUR-MAGNETIC-POLE MOTOR ALLOY FLAKE FOR RARE EARTH MAGNET, PRODUCTION METHOD THEREOF, ALLOY POWDER FOR RARE EARTH SINTERED MAGNET, RARE EARTH SINTERED MAGNET, ALLOY POWDER FOR BONDED MAGNET AND BONDED MAGNET METHOD FOR MANUFACTURING BONDED MAGNET AND METHOD FOR MANUFACTURING MAGNETIC DEVICE HAVING BONDED MAGNET ISOTROPIC POWDERY MAGNET MATERIAL, PROCESS FOR PREPARING AND RESIN-BONDED MAGNET PATENT ANALYSIS TABLE 65-NUMBER OF U.S. PATENTS GRANTED TO COMPANIES IN THE PERMANENT MAGNET BUSINESS BY TYPE FROM 2009 THROUGH APRIL TABLE 66-NUMBER OF U.S. PATENTS GRANTED TO COMPANIES IN THE PERMANENT MAGNET BUSINESS FROM 2009 THROUGH APRIL FIGURE 10-TOP COMPANIES GRANTED U.S. PATENTS FOR PERMANENT MAGNETS FROM 2009 THROUGH INTERNATIONAL OVERVIEW OF U.S. PATENT ACTIVITY IN PERMANENT MAGNETS TABLE 67-U.S. PATENTS GRANTED FOR PERMANENT MAGNETS BY ASSIGNED COUNTRY/REGION FROM JANUARY 2009 TO APRIL COMPANY PROFILES ADVANCED TECHNOLOGY & MATERIALS CO., LTD (AT&M) xiv

15 ALLIANCE LLC ARNOLD MAGNETIC TECHNOLOGIES CORPORATION YANTAI ZHENGHAI MAGNETIC MATERIAL CO., LTD. (ZHMAG) YUXIANG MAGNETIC MATERIALS INDUSTRIAL LIMITED ZHEJIANG ANTE MAGNETIC MATERIAL CO., LTD DISTRIBUTORS AND FABRICATORS OF PERMANENT MAGNETS ADAM MAGNETIC PRODUCTS CO ALLSTAR MAGNETICS APPLIED MAGNETS NINGBO XIONGHAI MAGNETICS & MECHANISM INDUSTRIAL CO. LTD. 197 STANFORD MAGNETS VIONA MAGNETICS APPENDIX I: GLOSSARY OF TERMS APPENDIX II: QUANTITIES, SYMBOLS, UNITS AND CONVERSION FACTORS xv

16 LIST OF TABLES SUMMARY TABLE... 7 GLOBAL MARKET FOR PERMANENT MAGNETS... 7 TABLE 1 NOMINAL COMPOSITIONS, CURIE TEMPERATURES, AND MAGNETIC ORIENTATIONS OF SELECTED PERMANENT MAGNET MATERIALS TABLE 2 SUMMARY OF RANGE OF PROPERTIES OF PERMANENT MAGNET MATERIALS TABLE 3 NOMINAL MAGNETIC PROPERTIES OF SELECTED PERMANENT MAGNET MATERIALS TABLE 4 NOMINAL MECHANICAL AND PHYSICAL PROPERTIES OF SELECTED PERMANENT MAGNET MATERIALS TABLE 5 TERMS/DEFINITIONS RELATED TO PERMANENT MAGNETS TABLE 6 MAGNETIC PROPERTIES OF CHINESE CERAMIC MAGNETS TABLE 7 EQUIVALENT MAGNETIC PROPERTIES OF U.S. VS. CHINESE HARD FERRITE CERAMIC MAGNETS TABLE 8 APPLICATIONS OF HITACHI S RADIALLY ORIENTED RING CERAMIC MAGNETS TABLE 9 PRICING OF COMMERCIALLY AVAILABLE FERRITE PRODUCTS TABLE 10 MARKET SHARE OF TOP MANUFACTURERS OF FERRITE MAGNETS IN TABLE 11 GLOBAL MARKET OF HARD FERRITE PERMANENT MAGNETS, TABLE 12 MMPA DESIGNATIONS FOR RARE EARTH IRON-BORON MAGNETS TABLE 13 MAGNETIC CHARACTERISTICS OF TDK S NEOREC NDFEB MAGNETS TABLE 14 GLOBAL MARKET SHARE BY WEIGHT FOR NEODYMIUM-IRON- BORON MAGNETS BY APPLICATION TABLE 15 PRICE PATTERN OF COMMERCIALLY AVAILABLE NEODYMIUM- IRON-BORON PERMANENT MAGNETS PRODUCTS TABLE 16 GLOBAL MANUFACTURERS OF NDFEB MAGNETS TABLE 17 GLOBAL MARKET FOR NEO PERMANENT MAGNETS, 2013 AND xvi

17 TABLE 18 GLOBAL MARKET FOR NEODYMIUM-IRON-BORON MAGNETS BY APPLICATION, 2013 AND TABLE 19 RARE EARTH MAGNET DESIGNATIONS TABLE 20 NOMINAL COMPOSITION, CURIE TEMPERATURE AND ORIENTATION OF COMMERCIAL RARE-EARTH COBALT MAGNETS TABLE 21 NOMINAL PHYSICAL AND MECHANICAL PROPERTIES OF RE MAGNETS TABLE 22 NOMINAL MAGNETIC PROPERTIES OF RARE EARTH/COBALT MAGNETS TABLE 23 MAGNETIC PROPERTIES OF SOME COMMERCIALLY AVAILABLE RARE EARTH COBALT MAGNETS TABLE 24 GLOBAL MANUFACTURERS OF SAMARIUM-COBALT MAGNETS TABLE 25 GLOBAL MARKET OF SAMARIUM-COBALT PERMANENT MAGNETS TABLE 26 ALNICO MAGNET DESIGNATIONS TABLE 27 NOMINAL COMPOSITION, CURIE TEMPERATURE AND MAGNETIC ORIENTATION OF CAST ALNICOS TABLE 28 MAGNETIC PROPERTIES OF CAST ALNICO MAGNETS TABLE 29 NOMINAL PHYSICAL AND MECHANICAL PROPERTIES OF CAST ALNICO MAGNETS TABLE 30 NOMINAL COMPOSITION, CURIE TEMPERATURE AND MAGNETIC ORIENTATION OF SINTERED ALNICOS TABLE 31 MAGNETIC PROPERTIES OF SINTERED ALNICO MAGNETS TABLE 32 NOMINAL PHYSICAL AND MECHANICAL PROPERTIES OF SINTERED ALNICO MAGNETS TABLE 33 PRICE PATTERN OF COMMERCIALLY AVAILABLE ALNICO PRODUCTS TABLE 34 LEADING GLOBAL MANUFACTURERS OF ALNICO MAGNETS TABLE 35 GLOBAL MARKETS OF ALNICO PERMANENT MAGNETS TABLE 36 POWDER SPECIFICATIONS OF BONDED FERRITE TABLE 37 APPLICATIONS FOR TYTEK INDUSTRIES MAGNETS TABLE 38 APPLICATIONS FOR TDK S COMPOSITE MAGNETS TABLE 39 AVERAGE PRICES OF FERRITE, SMCO AND NDFEB BONDED MAGNETS xvii

18 TABLE 40 LEADING MANUFACTURERS OF BONDED MAGNETS IN CHINA, EUROPE, JAPAN, THE U.S., AND THE REST OF THE WORLD TABLE 41 GLOBAL MARKET FOR PERMANENT BONDED MAGNETS TABLE 42 MAGNETIC PROPERTIES OF IRON-CHROMIUM-COBALT MAGNETS TABLE 43 MAGNETIC PROPERTIES OF HITACHI IRON-CHROMIUM- COBALT MAGNETS TABLE 44 PHYSICAL AND MECHANICAL PROPERTIES OF REMALLOY TABLE 45 PHYSICAL AND MECHANICAL PROPERTIES OF CUNIFE TABLE 46 PHYSICAL AND MECHANICAL PROPERTIES OF CUNICO TABLE 47 PHYSICAL AND MECHANICAL PROPERTIES OF VICALLOY TABLE 48 NOMINAL COMPOSITIONS, CURIE TEMPERATURES AND MAGNETIC ORIENTATION OF MAGNET ALLOYS TABLE 49 NOMINAL MAGNETIC PROPERTIES OF MAGNET ALLOYS TABLE 50 NOMINAL COMPOSITIONS, CURIE TEMPERATURES AND MAGNETIC ORIENTATION OF MAGNET STEELS TABLE 51 NOMINAL MAGNETIC PROPERTIES OF MAGNET STEELS TABLE 52 NOMINAL MECHANICAL PROPERTIES OF PT-CO MAGNETS TABLE 53 MAGNETIC PROPERTIES OF PT-CO MAGNETS TABLE 54 MAGNETIC PROPERTIES OF MISCELLANEOUS PERMANENT MAGNET MATERIALS TABLE 55 RARE EARTH FREE NEW MAGNETIC MATERIAL RESEARCH TABLE 56 GLOBAL DISTRIBUTORS AND FABRICATORS OF HARD FERRITE, ALNICO AND BONDED MAGNETS TABLE 57 GLOBAL DISTRIBUTORS AND FABRICATORS OF NDFEB MAGNETS TABLE 58 GLOBAL DISTRIBUTORS AND FABRICATORS OF SM-CO MAGNETS TABLE 59 ACQUISITIONS, MERGERS, EXPANSIONS AND NEW RESEARCH FUNDING IN COMPANIES MANUFACTURING PERMANENT MAGNETS, 2009 TO JANUARY TABLE 60 APPLICATIONS AND MAJOR END USERS OF PERMANENT MAGNETS IN THE U.S., EUROPE AND JAPAN TABLE 61 CONTACT DETAILS FOR SOME SELECT END USERS OF PERMANENT MAGNETS IN THE U.S., EUROPE AND ASIA TABLE 62 GLOBAL MARKETS FOR PERMANENT MAGNETS xviii

19 TABLE 63 GLOBAL OUTPUT OF PERMANENT MAGNETS BY REGION IN TABLE 64 GLOBAL OUTPUT OF PERMANENT MAGNETS BY REGION IN TABLE 65 NUMBER OF U.S. PATENTS GRANTED TO COMPANIES IN THE PERMANENT MAGNET BUSINESS BY TYPE FROM 2009 THROUGH APRIL TABLE 66 NUMBER OF U.S. PATENTS GRANTED TO COMPANIES IN THE PERMANENT MAGNET BUSINESS FROM 2009 THROUGH APRIL TABLE 67 U.S. PATENTS GRANTED FOR PERMANENT MAGNETS BY ASSIGNED COUNTRY/REGION FROM JANUARY 2009 TO APRIL xix

20 LIST OF FIGURES SUMMARY FIGURE - GLOBAL MARKET FOR PERMANENT MAGNET SEGMENTS IN 2013 AND FIGURE 1 NEODYMIUM-IRON-BORON MAGNET PRODUCTION CYCLE FIGURE 2 CONVENTIONAL AND DIRECT DRIVE WIND TURBINES FIGURE 3 BONDED MAGNET PRODUCTION VIA EXTRUSION PROCESS FIGURE 4 BONDED MAGNET PRODUCTION VIA INJECTION MOLDING PROCESS FIGURE 5 BONDED MAGNET PRODUCTION VIA COMPRESSION MOLDING PROCESS FIGURE 6 BONDED MAGNET PRODUCTION VIA CALENDERING PROCESS. 96 FIGURE 7-GLOBAL MARKET FOR PERMANENT BONDED MAGNETS FIGURE 8 GLOBAL MARKET SHARE BY TYPE OF PERMANENT MAGNET FIGURE 9 MAGNET PRODUCTION BY REGION FIGURE 10 TOP COMPANIES GRANTED U.S. PATENTS FOR PERMANENT MAGNETS FROM 2009 THROUGH xx

21 INTRODUCTION Permanent magnets are a vital part of modern life. They are found in or used to produce almost every modern convenience today, from speakers in mobile phones to the electric motors in hybrid cars; air conditioners and washing machines. Permanent magnets are used increasingly in technological applications, including traveling wave tubes, Hall effect sensors, high temperature-resistant permanent magnets, thin-film coating equipment and flywheel storage systems. In all of these applications, it is important for the designed permanent magnet to be of high strength, resistive to corrosion, and resistive to demagnetization due to excessive heat. Manufacturers have gained experience in designing and producing permanent magnets to meet these needs for industries with permanent magnet and magnetic assembly applications. There are a number of major families of permanent magnets available for designers, ranging from ferrite, known for its low cost and low energy, to rare earth materials, which are more expensive and offer higher performance. Designers need to analyze magnetizing field strength and magnetic output of magnetic materials prior to deciding on the appropriate magnet. Permanent magnets today are 60 times as strong as they were about 90 years ago. Strong permanent magnets that can be used in industrial applications were developed in the 20th century, and Japanese and western European researchers and technologies have always played major roles in the development of permanent magnets. With the heavy reliance on Neo magnets in manufacturing, rare earth (RE) materials neodymium and dysprosium are playing a very important role because of the scarcity of these materials and the dominance of a single country (China) in providing them. The permanent magnet industry will start to see the end of serious RE shortages as new supplies begin to hit the market during 2013 and beyond, with new designs and new materials. STUDY GOALS AND OBJECTIVES This irap report has been prepared to highlight the many new developments in the permanent magnet industry. Many of the market segments are mature, while others are growing at very fast rates. Developing economies such as China and India are also emerging as growth engines for many industries that use permanent Copyright 2014 Innovative Research and Products (irap), Inc., Stamford, CT, USA 21

22 magnets. The markets in these new economies are expected to experience maximum revenue growth during the next five years. Secondly, there are new applications for permanent magnets such as voice coil motors, traveling wave tubes, wind turbine generators, hybrid and pure electric vehicle motors, water turbine generators, thin-film coating equipment and flywheel storage systems applications. These have created the need for a formal analysis of technological and business issues, trends in manufacturing, competitive landscapes and Chinese domination in global markets, as well as factors such as shortages of raw materials used in Neo magnets. This report has been prepared to: provide an overview of the various permanent magnets, their production technologies and applications; identify the technological and business issues related to the commercial production of permanent magnets; understand the inter-material competition among the various permanent magnets; determine the current size and future growth of the global markets for permanent magnets till 2018; identify and profile global producers, distributers, fabricators and suppliers of permanent magnets; assess new global funding in research of RE-free permanent magnet materials; and illustrate US patents in this field that were granted between 2009 and CONTRIBUTIONS OF THE STUDY This technical/economic study covers technical and industry overviews, materials, current and emerging production methods, business and technology issues, current and emerging applications, industry structure and an extensive market analysis. Current size and future growth of the global markets are estimated for 2013 and Copyright 2014 Innovative Research and Products (irap), Inc., Stamford, CT, USA 22

23 FORMAT AND SCOPE This report reviews the technology of permanent magnet materials, types of permanent magnet materials and their applications, and current and anticipated demand for specific materials. For each material segment, the report provides an analysis of material and product types in that category, processing technologies, properties, applications, the global markets and foreign competition. The qualitative and quantitative judgments embodied in this report are a valuable contribution to the current knowledge of permanent magnets, their manufacturing technologies, applications and markets. Moreover, this study has been conducted at a vital stage when new magnet materials such as neodymium-iron-boron are revolutionizing applications. Because of the miniaturization of electronic components and computers, more powerful and smaller magnets are needed for such applications. This current study identifies all such applications. Company profiles of all global producers of permanent magnets are covered, along with major distributors, fabricators and a listing of leading consumers of permanent magnets. METHODOLOGY AND INFORMATION SOURCES The findings of this report are based on information derived from interviews with almost all producers, distributors and major users of permanent magnets. Several industry experts were also contacted for this study. In all, about 150 persons from 100 companies were contacted for this study. Secondary data were obtained from industry associations such as the U.S. Magnetic Materials Producers Association (MMPA); American Society of Materials (ASM); trade publications from China, Germany and the U.S.; technical journals such as Nature, Advanced Materials, MIT-Technology Review, Machine Design, Spectrum and others; and government statistics from agencies such as the U.S. Department of Commerce (Bureau of the Census) and the U.S. International Trade Administration, and Japanese, Chinese and European publications. WHO SHOULD SUBSCRIBE This report is directed to companies that are interested in the developments in this field such as: companies involved in the development, manufacturing and supplying of advanced materials; Copyright 2014 Innovative Research and Products (irap), Inc., Stamford, CT, USA 23

24 manufacturers and suppliers of permanent magnets; manufacturers and suppliers of systems and subsystems which incorporate permanent magnets; manufacturers and suppliers of raw materials for permanent magnets; importers and suppliers of permanent magnets; users of permanent magnets; and advanced materials companies interested in diversification. AUTHOR S CREDENTIALS Analyst B.L. Gupta, Bachelor of Engineering, mechanical engineer, has 35 years of R&D experience in key positions and has handled high-tech product development in a number of fields. Before starting his own consultancy in 2001, Gupta worked with leading ISO-9000 certified multinational companies. He has been a member of the American Society of Mechanical Engineers since 1996; a Charter Engineer and Fellow of the Institution of Engineers (India) since 2001; a member of the Consulting Development Centre, a Government of India Society, since 2000; and a member of the Bureau of Indian Standards working on formulation of national standards on printing presses and allied subjects since Between 2010 and 2012, he worked as a national consultant with the United Nations Industrial Development Organization (UNIDO-ICAMT) Indian branch on technology upgrades and a productivity enhancement project of machine tool manufacturing units. Market research studies conducted by the author include: Electroactive Polymer Actuators and Sensors 2013 Types, Applications, New Developments, Industry Structure and Global ; Advanced Solid-State Memory Systems and Products: Emerging Non-Volatile Memory Technologies, Industry Trends and Market Analysis, ; Thin-Film Batteries A Global Technology, Industry and Market Analysis, ; Piezoelectric Actuators and Motors Types, Applications, New Developments, Industry Structure and Global, ; Ultra-Low Power Energy Harvesting for Wireless Switches and Wireless Sensor Networking Electric Power Harvesting Types, Applications, New Developments, Industry Structure and Global ; Large-Format Lithium-Ion Batteries Types, Applications, New Developments, Industry Structure and Global ; Nano-Enabled Batteries Types, Applications, New Developments, Industry Copyright 2014 Innovative Research and Products (irap), Inc., Stamford, CT, USA 24

25 Structure and Global ; Silicon MEMS Oscillators A Global Technology, Industry and Market Analysis; Piezoelectric Quartz Crystals and Devices A Global Technology, Industry and Market Analysis; Piezoelectric Ceramics, Polymers and Ceramic/Polymer Composites and Devices A Global Technology, Industry and Market Analysis; MEMS Microphones A Global Technology, Industry and Market Analysis, ; Electroactive Polymer Material and Devices, ; Micro Fuel Cells for Handheld Consumer Electronic Products A Technical Economic Analysis, ; Ultracapacitors, ; Auto Electric Products A Global Industry and Market Analysis, ; Global Market for Hybrid Electric Vehicle Components, ; Global Market for Automotive Sensors, ; Global Market for Automotive Semiconductors, ; and U.S. Market for Industrial Sensors, Copyright 2014 Innovative Research and Products (irap), Inc., Stamford, CT, USA 25