Sm2Fe17N3 Magnet Production: Hot Pressing vs. Spark Plasma Sintering

data grid shows cost breakdown for SmFeN magnet production
Cost breakdown for SmFeN magnet production

CMI researchers at Ames National Laboratory conducted the activity for this highlight

Innovation  
Hot pressing was assessed as a scalable, cost-effective, and energy-efficient alternative to spark plasma sintering (SPS) for Sm2Fe17N3 magnet production.

Achievement

  • Hot pressing Sm2Fe17N3 magnet shows similar densities and magnetic properties with SPS: Hci=10.9 kOe, and BHmax=24 MGOe at small scale.
  • Since hot pressing is easily scaled compared to SPS, techno-economic analysis (TEA) and life cycle assessment (LCA) assumed production of 90 metric tons of Sm2Fe17N3 magnets per year.
    • Hot pressing reduced production costs by 65% - 86% compared to SPS due to reduced labor and capital costs. 
    • Hot pressing reduced environmental impacts compared to SPS.

Significance and Impact

  • Recommended hot pressing for sintering Sm2Fe17N3 magnet.
  • Next step is to experimentally validate scalability.

Hub Target Addressed 

  • Accelerated magnet discovery and maturation.
  • Assessing economic, environmental, and social acceptance impacts.
diagram shows comparative life cycle impact assessment for producing 1 kg of SmFeN, SmCo, and NdFeB magnets
Comparative life cycle impact assessment for producing 1 kg of SmFeN, SmCo, and NdFeB magnets