Novel SmCo manufacturing method improves economic competitiveness

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Annual net cash flow for different levels (X% wt.)  of CM powder addition (NPV of all cash flows indicated)
Annual net cash flow for different levels (X% wt.)  of CM powder addition (NPV of all cash flows indicated)

CMI researchers at Ames Laboratory, Iowa State University and Purdue University conducted the research for this highlight

Achievement
Techno-economic assessment of a new method for samarium-cobalt magnet processing indicates significantly improved profitability compared to the traditional approach.

Significance and impact
Increasing the mechanical strength of SmCo magnets by incorporating cryomilled (CM) powders during processing results in a lower defect rate, while maintaining compatibility with existing manufacturing methods. The reduced production costs provide a substantial competitive advantage.

Details and next steps

  • The lower failure rate ensures profitability when the SmCo selling price is =$90/kg; the traditional method requires $123.5/kg.
  • Design of Experiments will be applied for further improvement of economic performance.
     
Sensitivity analysis for different powder additions and magnet material selling price ($/kg)
Sensitivity analysis for different powder additions and magnet material selling price ($/kg)