BondedMagnets:CurrentStatus

andFutureDevelopments
Dr.JohnOrmerod
SeniorTechnologyAdvisor
MagnetApplications,Inc.

PresentationOutline
Introduction:whoamIandwhoisMAI?
Whatarebondedmagnetsanyway?
Isthereanythingnewinmagnets(bondedor
otherwise)?
Whatarethemarketandapplicationdrivers?

Introduction:JohnOrmerod
BSc,MSCandPhDinMetallurgyfromtheUniversityofManchester(1972 1978).
MagneticscareerbeganwithPhilips(UKandHolland) 1979 1990.
DevelopedandcommercializedSmCo5,2:17andNdFeBmagnets

JoinedArnoldEngineering(US)responsibleforsoftandhardmagneticmaterialsdevelopmentandGMfor
permanentmagnets(1990 2002).
2002 2014PresidentofResManufacturinginMilwaukee.
Metalstampingandvalueaddedassembliestotheautomotivemarket(Toyota,GM,Nissan)
MajorsuppliertoTeslaMotorsforModelSandfutureModelX

RecentlyprovidedexperttestimonyonissuesofinvalidityduringtherareearthmagnetITCinvestigationand
currentlyadvisingtheRareEarthMagnetAllianceonpriorartrelativetoHitachiMetalskeypatents.
AdvisoryBoardmemberforBuntingMagnetics,SeniorTechnologyAdvisorforMAIandTechnologyAdvisor
forNironMagnetics.
Foundedbusinessandtechnologyconsultancyformagneticsandmetalsrelatedindustriesin2015 JOCLLC
(www.jocllc.com).

Introduction:MagnetApplications,Inc.
Visitthewebsiteat:http://magnetapplications.com.
ABuntingMagneticsCompany:https://buntingmagnetics.com/.
LargestNorthAmericanmanufacturerofcompressionbonded
NdFeBandinjectionmoldedferriteandNdFeBmagnets.
Supplyfullrangeofengineeredmagnetsandmagnetic
assemblies.
LocatedinDuBois,PA OriginallyestablishedinUKover50years
ago sistercompanylocatedinBerkhamsted,UK.
PrimaryapplicationsareBLDCmotorsandsensorsinthe
automotive,medicalandindustrialmarkets.

Introduction:MagnetApplications,Inc.
Preproductionmagneticdesignservicesincluding3Dmagnetic
modeling.
Industryleadingtechnicalservicestooptimizethematerialforthe
application.
InvestinginR&Dfornextgenerationofmagneticmaterials.
Thebackingofstrongfamilyownership inbusinessforover55
years.
ITAR/DFARSregisteredforDefenseIndustry.
ISO9001CertifiedQualitySystemwithcontinuousimprovement.
Verystronginternationalsupplychainforthecompleterangeof
permanentmagnetmaterials.

PresentationOutline
Introduction:whoamIandwhoisMAI?
Whatarebondedmagnetsanyway?
Isthereanythingnewinmagnets(Bondedor
otherwise)?
Whatarethemarketandapplicationdrivers?

WhatAreBondedMagnetsAnyway?
Bondedmagnetsarecompositesofapermanentmagneticpowder(s)embeddedinanon
magneticmatrix.
Thematrixistypicallyathermoplasticorelastomericbinder.
Commonprocessingtechniquesareextrusion,injectionmolding,compressionbonding,and
calendering.
Exhibitexcellentmechanicalpropertiescomparedtofullydenserareearthandferritemagnets.
Endproducthasgoodfinishanddimensionaltolerancesrequiringnofinishingoperations.
Injectionmoldedmagnets canbeformedintocomplexshapesandbeinsertorovermolded
directlyontoothercomponentstoproduceassemblies.
Thenonmagneticbinderlowersthedensityofthemagnetanddilutesthecontributionofthe
magneticpowder.
Theygeneratelessmagneticoutputperunitvolumethanfullydensemagnets.
ThetwomostcommonmagneticpowdersareisotropicNdFeBandhardferrite.

Bondedvs.Sintered
Bonded
Excellentgeometrictoleranceswith
minimalornosecondaryoperations
Goodmechanicalproperties
Complexshapes
Insert/overmolding ofsubassemblies
Higherelectricalresistivity
Multipolemagnetization
Tailoredfluxoutputforgiven
size/shapemagnet

Sintered
Highestfluxoutput
Higheroperatingtemperature

IsotropicMagnets
Definition:Isotropyisuniformityinallorientations;equalpropertiesinall
directions.
Somemagnetsdonothaveapreferreddirectionofmagnetization;equal
fluxoutputinalldirectionswhenmagnetized.
Thesearereferredtoasisotropic(ornonoriented)magnets.

VastmajorityofbondedNdFeBmagnetsareisotropic.
Individualpowderparticlesconsistofnumerousrandomlyorientedcrystalgrains.

Maybemagnetizedinanydirectionwithequaloutput.
Arectangularmagnetmaybemagnetizedthroughthewidth,thicknessorlengthandmaintainthe
sameintrinsicpropertiesofmagnetization.
Thisisaveryusefulcharacteristicforbuildingmultipoledevicesoutofasinglepieceofmagnetic
material.
Wehavedevelopedmultipoleringswithupto102polesat0.8mmpolepitch.

AnisotropicMagnets
Definition:Anisotropyisexhibitingpropertieswithdifferentvalues
whenmeasuredindifferentdirections,asopposedtoisotropy,which
impliesidenticalpropertiesinalldirections.
Magnetshaveapreferreddirectionofmagnetization
Referredtoasananisotropicororientedmagnet.
Duringmanufacturesinglecrystalgrainsofthematerialarealignedtomaximizethe
fluxdensityoutputofthemagnet.
Requiresmagnetizationparalleltothealignment.
Strongermagneticoutputthanisotropic.

VastmajorityofsinteredNdFeBmagnetsareanisotropic.

BondedMagnetMaterialAndProcessOptions
Binder

Thermoplastic

Thermoset
Epoxy
Phenolic
Novalac

Process

Compression
(Hoption)

Polyamides
PPSPolyolefin

Injection

Elastomer
NitrileRubber
Polyethylene
Vinyl

Extrusion

Calendering

(Hoption)

End
Product

Rigid

Rigid

Rigid

Flexible

Typical
Magnetic
Powders

NdFeB
SmCo
SmFeN
Hybrids

NdFeB
SmCo
Ferrite
Alnico
Hybrids
SmFeN

NdFeB
Ferrite
Alnico

NdFeB
Ferrite
Hybrids

InjectionMolding

COMPOUND

MOLD
CLAMPING
PRESSURE

MOLDED
PART

HEATING SYSTEM
INJECTION
STROKE

Extrusion
Granulatedcompound

COMPOUND

HEATED
DIE

TO COLLECTION

HEATING SYSTEM

Calendering
Granulatedcompound

FEED

TO COLLECTION
TAKE-OFF ROLL

CompressionBonding
HYDRAULIC OR
MECHANICAL RAM

PUNCH

DIE

Encapsulatedpowder

PRESS FRAME

CompressionBondingorInjectionMolding?
InjectionMolding
Complexformswithgood
geometricaltolerances
Multicavitytooling
Overandinsertmolding
But
Expensivetooling
Lowermagnetics(66%volume
loadingofmagneticpowder)
NdFeBandferrite

CompressionBonding
ThinwalledlargeL/Dratiorings
Simplelowcosttooling
Highermagnetics(75%volume
loadingofmagneticpowder)
But
Simplegeometries
Valueaddedoperationsduring
pressingverydifficult
NdFeBonly

PresentationOutline
Introduction:whoamIandwhoisMAI?
Whatarebondedmagnetsanyway?
Isthereanythingnewinmagnets(bondedor
otherwise)?
Whatarethemarketandapplicationdrivers?

IsThereAnythingNewinMagnets(BondedorOtherwise)?
Inthesummerof2011,thepriceofrareearthelementswas
skyrocketing,blastedupwardbyuncertaintiesaroundsourcing.
Whatgoesupmustcomedown,andtherareearthmarkethasdone
In2010,theChinesegovernmentcuttheexportquotaby
sowithavengeance.

40%.
Customersbegandoublingandtriplingorders,and
speculatorsmovedin.
Awidespreadmisconceptioninindustryholdsthatthe
bubbleformedbecausetheChinesegovernmentcurtailed
supply.
Thecutinexportquotaswastheprecipitatingeventbutit
wastheresponseofcustomersandthesupplychainthat
causedtheproblem,notanabsolutelimitationinthe
supply.
Source:K.Lewotosky,MCMA11/23/2015

IsThereAnythingNewinMagnets(Bondedor
Otherwise)?
However,itdidtriggeraGlobalresponsetospendmainlyother
peoplesmoney(ARPAE,DARPAE,EUREFREEPM)onthesearchfora
REfreeorreducedREcontentmagnet.
Sowhatsnewish (butnotyetcommercialized):
CeTM
MnBi
Nanocompositeexchangespring
OptimizedAlNiCo
FeN
CoFeCnanoparticles
Nanocrystalline MnAl
FeNi
HfCo
etc.,etc.

RecentDevelopment MnBi

CommerciallyImportantRecentDevelopments
NextGenerationLaCodopedhardferritemagnetse.g.HML,TDK

Dy diffusionprocessing ReducedDy contenthighoperatingtemperatureNdFeB

magnets

WhatsNewinBondedMagnets?
RareEarthFreeFe16N2basedmagnets.
Applicationof3DPrinting/AdditiveManufacturingto
BondedMagnetsandAssemblies.
HigherEnergyProductCompressionBondedIsotropic
NdFeBmagnets.

SomeHistoryonFe16N2;TheSlaterPaulingCurve

23

magneticmomentperFe(B)

SomeHistoryofFe16N2
4.0
3.5
3.0
2.5 Fe

Fe16N2

Fe4N
Fe3N

2.0

Fe2N

1.5
0

10

20

30

40

Nat.%
StrangedeparturefromtheregularSPcurvewasclaimedbackin1970thatFe16N2
possessesagiantMs,correspondingtoanaveragemagneticmomentof2.9~3.5B/Fe
accordingtodifferentreports.
24

40YearsLaterNoFe16N2Magnet Why?
DifficulttosynthesizepureFe16N2byconventionalmethodse.g.solubility
ofNinliquidFeverylow(0.045versus5.5wt %forC).
Alloycannotbeformedbyconventionalprocessingmethodse.g.melting
andcasting.
Contradictoryresultsovertheyearsprobablyduetoinconsistentsample
preparationandmeasurementtechniques.
Fe16N2decomposesabove300C.
Cannotbeformedbypowdermetallurgicalprocessing.
LotsofmagnetizationavailablebutneedcoercivityforausefulPM
compound;theoreticalmagnetocrystallineanisotropyHis16kOe butwill
needhelpfromothermechanismse.g.shape,strain.

BulkFe16N2MagnetReportedbyUMNTeamand
NironMagneticsFormed
Strainedwiremethodusedtoenhance
magneticproperty;strainassisted
annealing.

Source:NironMagnetics

26

NironMagnetics GoodNews/BadNews

GoodNews
Thecompanyisproducingbulkiron
nitridemagnetstodayforfurther
researchanddevelopment.
Firstprinciplescalculations
demonstrateatheoreticalBHmax
of135MGOeandHc of16KOe.
Rawmaterialsarecheapand
abundant.
IsotropicbondedmagnetBHmax>
30MGOefeasible.

BadNews
Ironnitridebyitselfisinherently
heatsensitive.
Itdecomposesbeforeitsinters
ironnitridemagnetswillallbe
bondedinsomefashion.
Coercivityneedstobeimproved.
Theywillneedthesamecorrosion
protectionasrawiron.
Nironhasntannounceda
commercialproductyet

WhatsNewinBondedMagnets?
RareEarthFreeFe16N2basedmagnets.
Applicationof3DPrinting/AdditiveManufacturingto
BondedMagnetsandAssemblies.
HigherEnergyProductCompressionBondedIsotropic
NdFeBmagnets.

AdditiveManufacturing MAIandORNLJoint
RandDProject
MAI and ORNL were recently awarded a Cooperative Research and
Development award to study the application of additive manufacturing to
bonded magnets and systems.

3DPrintingProject
Goal:TofabricatenearnetshapeNdFeBmagnetsandtominimizethe
generatedwasteassociatedwithmagnetmanufacturingandreducethe
overallcost.
Oneofthewaysinwhichwecanachievethisgoalisbyusingadditive
manufacturing(AM)techniquestocreatecomplexshapesandgeometries
ofbondedmagnets.
Additivemanufacturingisthefabricationofgeometricallycomplex3Dobject
fromacomputeraideddesignwhichrequireslittleornotoolingandpost
processingthusreducingtheamountofwastegenerated.
Reducedtimetomarketfornewmagnet/motordesigners.

TypesofAM/3Dprinting

Source:ORNL

TypesofAdditiveManufacturing
ASTMInternational:
TechnicalCommitteeF42onAdditiveManufacturing

Vat Photo
polymerization
Material
Jetting
Binder
Jetting
Material
Extrusion
Source:ORNL

Powder Bed
Fusion
Directed Energy
Deposition
Sheet
Lamination

Indirect3DPrinting

Source:ORNL

ExOne BinderJetProcess
ExOne buildsfunctional3Dobjectsfromthebottomup,onelayeratatime
withdurable,industrialstrengthmaterials.
ExOne 3Dprintingsystemsselectivelybindthin,crosssectionallayersof
finepowder.
Astheprintheadpassesoverthepowderbed,binderisdepositedintothe
powder.
Thepowderbedlowersandiscoatedwithanotherlayeroftheprint
powder.
Witheachsuccessivepassoftheprinthead,moreoftheobjectisbound
untilanearnetshapeobjectiscompleted.

InitialMQPMagnetsProducedbyBinderJetting
per gram of composite
per gram of MQP assuming 60 wt %
200
150

Binderjet
MQP-resin

M (emu / g)

100
50
0
-50
-100
-150
i

-200
-40

-20

0
H (kOe)

Source:ORNL

HC = 9 kOe
20

40

Large Scale Polymer Deposition of Bonded Magnets

Theprocess:

Magnetizationbehaviorofthe
bondedmagnet

BAAMsystematORNL

Fabricatedrotors

Source:ORNL

PostMagneticfieldalignment(9Tesla)

36

ChallengesforDirectWriteInks

Inkmustflowthroughnozzlewithoutjamming
Inkfilamentsmustformhighintegrityinterfaces
Inkmustsolidifyrapidly(viagelation,coagulation,evaporation)
However,requirehighloading(>60volume%)ofmagneticpowder
Loadinglimitedto40volume%withstandardjetcastpowders
Currentfocusofresearchis:
Investigatingoptimumparticleshapeand
distribution
Correlationofbinderrheological
propertiesandpowdermagneticproperties

LargeScaleAdditiveManufacturing

3Dprintedallelectric
ShelbyCobracar
Whatsnext?
Permanentmagnetbasedmotors!!!
Source:ORNL

WhatsNewinBondedMagnets?
RareEarthFreeFe16N2basedmagnets.
Applicationof3DPrinting/AdditiveManufacturingto
BondedMagnetsandAssemblies.
HigherEnergyProductCompressionBondedIsotropic
NdFeBmagnets.

TypicalCompressionBondedMagneticProperties
Manysupplierspublish
specificationsforanominal
10MGOemagnetswitha
minimumlimitof9MGOe.
Similarforanominal11
MGOemagnet;minimum
limitis10MGOe.
Havetodesigntolower
limitofBHmax

BHmaxImprovementinCompressionBondedMagnets
TheBHmaxofacompressionbondedisotropicNdFeBmagnetis
influencedbythefollowingtwofactors:
1. Volumefractionofmagneticphaseinthemagnet typicallymeasuredby
thedensityofthemagnet.

Weareinvestigatingincreasingthepressingpressurewhichrequiresspecialpress
construction,lubricantsandtoolingmaterials currentproductionpressingpressures
are7tonnes/cm2for5.9g/cm3and10MGOe;estimatedthat>20tonnes/cm2
requiredfor6.3g/cm3and>11MGOe.
Optimizetheparticleencapsulationchemistryandprocess.
TailoredmultimodalPSDsformaximumpackingdensity.
Particleshapecontrol.

2. MagneticpowderBr/BHmax

IncreaseisotropicBrofpowderswhilemaintainingsufficientHci tohavelinearBH
demagnetizationcharacteristicattheapplicationtemperature.

20%BHmaxImprovement True11MGOe

Standardproductionnominalmagneticsat5.9g/cm3:
Br=6800G
Hci =9.1kOe
HcB =5.4kOe
BHmax=9.2MGOe

Highdensitynominalmagneticsat6.3g/cm3:
Br=7400G
Hci =9.1kOe
HcB =6.0kOe
BHmax=11.1MGOe

PresentationOutline
Introduction:whoamIandwhoisMAI?
Whatarebondedmagnetsanyway?
Isthereanythingnewinmagnets(bondedor
otherwise)?
Whatarethemarketandapplicationdrivers?

GlobalProductionOfPermanentMagnetsIn2014
MagnetType

Tonsx
1,000

%by
Weight

Million
USD

%by
Value

ASP $/Kg

SinteredNdFeB

70

10.9%

$10,500

54.8%

$150

BondedNdFeB

1.4

750

3.9

90

Sintered
/Bonded
Ferrite

565

87.6

6,780

35.4

12

Samarium
Cobalt

0.6

700

3.7

175

Alnico

0.9

420

2.2

70

TOTAL

645

100.0%

$19,150

100.0%

PMMarketsandDevices/Applications
Devices
Electromechanicalmachinesanddevices
e.g.motors,generators,actuators
Acoustictransducerse.g.speakers,
earphones,ringers
Mechanicalforceandtorquedevicese.g.
holding,lifting,clutches
Microwaveandionbeamcontrole.g.
TWTs,particleaccelerators
Conversionofexternalstimulito
electricalsignale.g.sensors
DCfieldgeneratione.g.MRI

MarketsandIndustries
Automotiveandtransportation
Industrialandcommercial
Consumerproducts
Militaryandaerospace
Medical

Sensors/Encoders
HallEffectEncoderforendofshaftapplications.Availableaseither
absoluteorincrementalencoderstheycanprovidedigitalposition,
analogposition,andquadraturespeedoutputs.Capableof
rotationalspeedsover20kRPM.HallICusedforthisapplicationuses
adiametricallymagnetizedmagnet.
HallEffectthroughshaftencoder.RequiresuseofHallICcapableofoff
axissensingusingmultipolebondedmagnet.
Lowcost,speedorpositionsensorstypicallyseeninautomotive
applications Camposition,crankposition,enginespeed,ABS.Thistype
ofsensorcanbedesignedforeitherfaceorlateralsensingapplications
andmay,inadditiontotheHallIC,incorporateamagnetifsensinga
metaltargetorapolepieceifsensinganencodermultipolemagnet.

Summary
Whatisthebestpermanentmagnetmaterialandprocess?
Itdepends;ontheweight/spacelimitations,applicationoperatingconditions,
operatingparametersofthemagneticcircuit,annualquantity,deviceassembly
mechanizationetc.
Despitehavelowerfluxoutputbondedmagnetscanofferadvantagesoversintered
magnetsformanyapplications.
Despitelackofbreakthroughinnewmaterialsoverthelast30yearsthereare
severalpromisingdevelopmentsinbondedmagnetsonthehorizon.
Alwaysdiscussyourspecificapplication/devicecriteriawithourSales/Application
Engineersbeforefreezinginamaterial.

THANKYOUFORYOURATTENTION ANYQUESTIONS