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Big Area Additive Manufacturing of High Performance Bonded NdFeB Magnets

TitleBig Area Additive Manufacturing of High Performance Bonded NdFeB Magnets
Publication TypeJournal Article
Year of Publication2016
AuthorsLi, L, Tirado, A, Nlebedim, IC, Rios, O, Post, B, Kunc, V, Lowden, RR, Lara-Curzio, E, Fredette, R, Ormerod, J, Lograsso, TA, Paranthaman, MP
JournalScientific Reports
Volume6
Pagination36212
Date Published10
Type of ArticleArticle
ISBN Number2045-2322
Accession NumberWOS:000386504800001
Keywordsb permanent-magnets, fe, mechanical-properties, nd, Technology - Other Topics
Abstract

Additive manufacturing allows for the production of complex parts with minimum material waste, offering an effective technique for fabricating permanent magnets which frequently involve critical rare earth elements. In this report, we demonstrate a novel method - Big Area Additive Manufacturing (BAAM) - to fabricate isotropic near-net-shape NdFeB bonded magnets with magnetic and mechanical properties comparable or better than those of traditional injection molded magnets. The starting polymer magnet composite pellets consist of 65 vol% isotropic NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm(3), and the room temperature magnetic properties are: intrinsic coercivity H-ci = 688.4 kA/m, remanence B-r = 0.51 T, and energy product (BH)(max) = 43.49 kJ/m(3) (5.47 MGOe). In addition, tensile tests performed on four dog-bone shaped specimens yielded an average ultimate tensile strength of 6.60 MPa and an average failure strain of 4.18%. Scanning electron microscopy images of the fracture surfaces indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binder. The present method significantly simplifies manufacturing of near-net-shape bonded magnets, enables efficient use of rare earth elements thus contributing towards enriching the supply of critical materials.

DOI10.1038/srep36212
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