UK Produced High Energy net-shaped PEMD Magnets by hot forming and the use of recycled materials

Neodymium based magnets made by sintering are well known. Having high remanence and coercivity, these "strong" magnets can be small. This project will pursue refinement of a newer process involving tightly controlled hot pressing of specially prepared Nd-Fe-B powder. This manufacturing method creates remarkable changes in the nanoscopic crystal structure of the material, producing magnetic properties that are highly appealing for a number of applications, such as electric vehicle drive motors, multiple automotive electrical systems, energy generation and consumer products.

Electrification in many products and sectors has raised a demand for such magnets. In addition to their impressive magnetic properties, hot-formed Neodymium magnets have the vital advantage of not requiring heavy rare earth elements such as Terbium and Dysprosium. Eliminating the need for these metals further entrenches supply chain security to the UK, as well as avoiding the environmental concerns regarding mining and refining these elements.

Supply chain security and autonomy are vital for providing consistent production capability for domestic manufacturers of high-quality electronics. Hence, for the move to electrification to proceed reliably, domestic large-scale production of these magnets will need to be demonstrated.

This project will embed production of these magnets in the UK supply chain by combining the specialised processing and application expertise shared by SG Technologies -- the UK's primary Neodymium magnet manufacturer -- the Magnetic Materials Group (MMG) at the University of Birmingham, and ZF Automotive UK Limited. Collaboratively, the ability to perform this production process at scale will be demonstrated at SG Technologies with the aid of the metallurgical expertise from the MMG to assist.

Additionally, with the assistance of HyProMag, the MMG will demonstrate the possibility of utilising recycled magnetic material as raw material for this production process. The one-of-a-kind technology developed here will further seek to decrease the environmental impact of magnet production, reducing waste and provide further independence to the UK supply chain.

The unique expertise in press technology at SG Technologies will make possible the production of a bespoke electric, computer-controlled press capable of high-volume manufacturing of net-shaped, hot-formed magnets, pathing a route towards UK industrial production capability. ZF Automotive UK Limited will take this further by evaluating products where these magnets may be suitable in applications, as well as simulating their performance in applications and thorough characterisation of the magnetic properties of the hot-formed magnets produced. Design of future devices and technologies will also be considered in this context.