Cost Effective Materials Based on NdFeB Compounds · Cost Effective Materials Based on NdFeB...

Bernd Grieb, Magnequench GmbH, Germany N. Sheth, D. Brown, H. Feng, Y. Keat, J. Herchenroeder, M. Chen, D. Miller Magnequench Intl. Inc., Pendleton, IN, USA Cost Effective Materials Based on NdFeB Compounds Magnet Materials in Electrical Machine Applications June 16th, 2012 Pori, Finland

2

Company Structure (June 8th, 2012)

Headquarters Toronto, Canada

Where We Fit in the Process Chain

• Quality

• Specifications

• Performance

Neo Powders

RE Separation Concentrate

Work with Our Customers

Rare Earths, Zirconium,

Rare Metals

Bonded Neo Magnets

Components/ End Products

MINING COMPANIES

CUSTOMERS

PROPRIETARY TECHNOLOGIES

Global Presence

9 Production Centres

13 Sales / Admin Offices

6 R&D Centres

5

Rare Earths

• JAMR (Jiangyin, Jiangsu Province) – “Heavy” Rare Earths – Ionic Clay Feedstock – Capacity = 3,000 mT TREO – Purity = 3 - 6N – 450 employees – Quality = ISO 9001:2000, 14000 – Post treatment processes such as:

• (co-) precipitation • hydrothermal Aging • Drying • Calcining • Milling • sieving

JAMR

ZAMR (Zibo, Shandong Province) • “Light” Rare Earths • Bastnaesite/RE Carbonate feed • Capacity: 3,000 tonnes (REO) • Purity: 2N-3N5 • ISO 9001:2000 • 395 employees • Main Markets

• Auto catalyst • FCC catalyst • Styrene Catalyst • Surface Finishing • Magnetics • Ceramic Pigments • Paint Dryer

Research and Development 24 researchers located in 6 development centres: Abingdon – Oxfordshire, UK Singapore ZAMR, JAMR, Tianjin (China) Peterborough (USA)

Development Initiatives Automotive catalyst Electronics (MLCC, sensors, CMP) Phosphors

6

Rare Metals

• Products – Gallium Metal 4N-7N purity – Gallium Nitrate – Gallium Tri-Chloride – Gallium Oxide – Indium – Rhenium

• Services – Recycling – Tolling – Upgrading – Process Development

• Products – Tantalum – Niobium – Rhenium – Hafnium – Gallium – Indium – Germanium

Services • Recycling • Trading • Upgrading

http://www.buss-spezialmetalle.de/index.html

http://www.recapturemetals.ca/

Magnequench Magnet Materials

• Capacity – 6,700MT • 330 employees • 5 alloy furnaces • 10 jet casters • ISO 9002 • ISO 14000 • RoHS Directive 2002/95/E • Accredited by SGS

MQTJ – Tianjin, China MQK – Korat, Thailand

• Capacity – 2,300MT • 115 employees • 3 jet casters (additional JC available) • ISO 9001 • ISO 14001 • RoHS Directive

8

Magnequench Powder Production Melt Spun Atomization

9

Melt-Spun RE-Fe-B Powder

The Nd2Fe14B based powders are typically crushed to <200µm and have an isotropic 20-30nm nanocrystalline structure.

10

106

105

104

103

102

10

1

Que

nchi

ng R

ate

(deg

C/s

ec)

Ingot Casting Strip Casting Atomization Jet Casting Grain Size

Complexity of Alloy

1cm 10 nm

10+ elements 1 or 2 elements

Microstructural Uniformity Homogeneity Segregation, coring

Highly Uniform structure

Grains 10-100nm

Thin Ribbon/flake form

Less Glass formers needed Uniform microstructure

Grains 100nm

Spherical form Segregated/Cored microstructures

Grains 1-100mm

Ingot form

Need for glass-formers (TiC, Zr)

Uniform columnar microstructure

Grains 1-0.1 mm

Thick flake form

10 mm

Reasons for Melt-Spinning RE-Fe-B

50 um 100 um 100 um

11 Page 18

MQP Powder Grades

2011 New Powder Grades (MQ1)

• High Temperature Powders – MQP-13-14-20203 – MQP-14.5-13-20202 – MQP-14-13-20201

• High Density Powders – MQP-16-9HD-20177 – MQP-15-9-HD-20178 – MQP-13-9HD-20179 – MQP-10-8.5HD-20180 – MQP-12-8-HD-20175

• PrNd Based Powders – MQP-B-20173 – MQP-B-20172

• Lower cost, stable price MQP range – MQP-13-9-20143 – MQP-8-5-20159 – MQP-7-8-20171

Overview

MQP-14.5-10MQP-14-9

MQP-13-9-20143MQP-13-9-20135

MQP-12-8.5MQP-11-7

MQP-10-7MQP-6.5-5

MQP-16-9HDMQP-15-9-HD

MQP-8-5MQP-7-8

MQP-B-20172

MQP-B-20173

MQP-13-9HDMQP-12-8-HD

MQP-10-8.5HD

MQP-13-14MQP-14.5-13

MQP-14-13

MQP-B+

0

2

4

6

8

10

12

14

16

18

20

0.0 2.0 4.0 6.0 8.0 10.0 12.0Magnet BHmax

Low

erin

g Co

st

Improving Performance

High Density PowdersPrNd Based PowdersLow Cost, Stable Price Powders

High Temperature Powders


• Designed for a variety of automotive applications or applications that require to operate at higher temperature

• Higher temperature stability

• Lower cost alternative to MQP-14-12-20000 by composition

Powder Magnet

Br

(kG) Hci

(kOe) (BH)max (MGOe)

Density (g/cc) Springback Br

(kG) Hci


MQP-14-12-20000 8.40 12.3 14.5 6.09 0.64% 6.92 11.8 10.0 MQP-13-14-20203 8.05 14.0 13.3 6.01 0.67% 6.47 13.9 8.8 MQP-14.5-13-20202 8.45 12.8 14.7 6.06 0.64% 6.91 12.5 10.0 MQP-14-13-20201 8.34 12.7 14.1 6.04 0.65% 6.82 12.4 9.6

Properties

Powder Curves Magnet Curves

0

2

4

6

8

10

-16 -14 -12 -10 -8 -6 -4 -2 0

B-H

(kG

)

H (kOe)

MQP-14-12-20000

MQP-13-14-20203

MQP-14.5-13-20202

MQP-14-13-20201

0

2

4

6

8

10

-16 -14 -12 -10 -8 -6 -4 -2 0

B-H

(kG

)

H (kOe)

MQP-14-12-20000MQP-13-14-20203MQP-14.5-13-20202MQP-14-13-20201

Aging at 1000 hours (PC=2)

-2,0-1,8-1,6-1,4-1,2-1,0-0,8-0,6-0,4-0,20,0

0 200 400 600 800 1000

Flux

Los

s (%

)

Time (Hours)

Aging Loss at 80oC

MQP-14-12-20000MQP-13-14-20203MQP-14.5-13-20202MQP-14-13-20201

-4,0

-3,5

-3,0

-2,5

-2,0

-1,5

-1,0

-0,5

0,0

0 200 400 600 800 1000

Flux

Los

s (%

)

Time (Hours)

Aging Loss at 120oC

MQP-14-12-20000MQP-13-14-20203MQP-14.5-13-20202MQP-14-13-20201

-8,0

-7,0

-6,0

-5,0

-4,0

-3,0

-2,0

-1,0

0,0

0 200 400 600 800 1000

Flux

Los

s (%

)

Time (Hours)

Aging Loss at 150oC

MQP-14-12-20000MQP-13-14-20203MQP-14.5-13-20202MQP-14-13-20201

B/µoH=-2

B/µoH=-2 B/µoH=-2


High Density Powders

Powders for High Density Magnets

• Magnets are more dense than typical magnets from other MQP grades Higher relative magnet properties Springback is lower Ejection forces are lower

Cost optimized Lower cost options based on NdPrZrFeB alloy

composition are also available

MQP-16-9-HD and MQP-15-9HD: Highest performing magnet properties

Powder Name

Powder Magnet (PC=2 magnet) Magnet/ Powder

Ratio Br Hci (BH)max Br Hci (BH)max Springback (OD) Springback (ID) Density

(kGs) (kOe) (MGOe) (kGs) (kOe) (MGOe) % % g/cc %

MQP-16-9HD-20177 8.78 9.4 15.5 7.13 9.1 10.4 0.84 0.57 5.97 78.8

MQP-15-9-HD-20178 8.72 9.3 15.3 7.04 9.3 10.2 0.89 0.63 6.01 78.5

0

2

4

6

8

10

-15 -10 -5 0 5

B-H

(kG

)

H(kOe)

Powder

MQP-16-9HD-20177MQP-15-9HD-20178

0

2

4

6

8

10

-15 -10 -5 0

B-H

(kG

)

H (kOe)

Magnet

MQP-16-9HD-20177MQP-15-9HD-20178

MQP-16-9HD and MQP-15-9HD

• Density of HD Powders is higher than MQP at a given pressure

5,4

5,6

5,8

6,0

6,2

7 8 9 10 11 12 13 14 15

Mag

net D

ensi

ty (g

/cc)

Pressure (t/cm2)

MQP-16-9HD-20177

MQP-15-9HD-20178

MQP-B+-10118

MQP-B+-20056

MQP-16-9HD and MQP-15-9HD: Magnet Properties

• Magnet properties are comparable and even better than the highest performing MQP grades (MQP-B+ family)

9,0

9,2

9,4

9,6

9,8

10,0

10,2

10,4

10,6

10,8

11,0

7 8 9 10 11 12 13 14 15

Mag

net (

BH

) max

(MG

Oe)

Pressure (t/cm2)

MQP-16-9HD-20177MQP-15-9HD-20178MQP-B+-10118MQP-B+-20056

6,0

6,2

6,4

6,6

6,8

7,0

7,2

7,4

7,6

7 8 9 10 11 12 13 14 15

Mag

net B

r (kG

)

Pressure (t/cm2)

MQP-16-9HD-20177MQP-15-9HD-20178MQP-B+-10118MQP-B+-20056

Other High Density Powder Grades

Powder Name

Powder Magnet (PC=2 magnet) Magnet/ Powder

Ratio Br Hci (BH)max Br Hci (BH)max Springback

(OD) Springback

(ID) Density (kGs) (kOe) (MGOe) (kGs) (kOe) (MGOe) % % g/cc %

MQP-13-9HD-20179 8.27 9.2 13.6 6.67 9.0 9.0 0.94 0.62 5.98 78.9 MQP-12-8-HD-20175 7.80 8.1 11.9 6.29 8.1 7.9 0.93 0.56 6.00 79.1 MQP-10-8.5HD-20180 7.15 8.5 9.9 5.79 8.3 6.7 0.96 0.69 5.99 78.6

0

2

4

6

8

10

-12 -10 -8 -6 -4 -2 0

B-H

(kG

)

H (kOe)

Powder

MQP-13-9HD-20179MQP-12-8-HD-20175MQP-10.5-8.5HD-20180

0

2

4

6

8

10

-10 -8 -6 -4 -2 0

B-H

(kG

)

H (kOe)

Magnet

MQP-13-9HD-20179MQP-12-8-HD-20175MQP-10-8.5HD-20180


PrNd Based MQP New powder grades based on NdPr

What is PrNd’s advantage versus Nd?

• Supply of PrNd is greater than Nd or Pr

• PrNd is a natural pair of elements in RE deposits – RE separators need to process PrNd into Nd and Pr

• Price of PrNd in long run should remain below prices of Nd and Pr

• Very similar performance achieved with PrNd based MQP compared with Nd or Pr based MQP

The expanded B family

Powder Type Powder Magnet

Br (kG)

Hci (kOe)

(BH)max (MGOe)

Springback (%)

Density (g/cc)

Br (kG)

Hci (kOe)

(BH)max (MGOe)

Nd

Bas

ed MQP-B-20029 8.88 9.5 15.3 0.72 5.97 7.00 9.1 9.8

MQP-B-20052 8.73 10.6 15.0 0.71 5.98 7.01 10.4 10.3

MQP-B- 20076 8.87 9.3 15.2 0.66 5.96 7.14 9.2 10.2

PrN

d B

ased

MQP-B-20172 8.71 10.6 15.0 0.71 5.96 7.03 10.3 10.3

MQP-B-20173 8.93 9.1 15.1 0.64 6.01 7.19 9.2 10.4

MQP-B-20052 and MQP-B-20172 (Formerly known as B3)

• Similar powder and magnet properties

0

2

4

6

8

10

-12 -10 -8 -6 -4 -2 0

B-H

(kG

)

H (kOe)

Powder

MQP-B-20052 (Nd based)MQP-B-20172 (PrNd based)

0

2

4

6

8

-12 -10 -8 -6 -4 -2 0

B-H

(kG

)

H (kOe)

Magnet

MQP-B-20052 (Nd based)MQP-B-20172 (PrNd based)

Note: Development powders; mass production powder properties may vary

MQP-B-20052 and MQP-B-20172 (Formerly known as B3) Aging Loss of PC=2 magnets

-12

-10

-8

-6

-4

-2

0

0 10 20 30 40 50 60 70 80 90 100

Agin

g lo

ss (%

)

Test time (hours)

MQP-B-20052 (Nd based) 120C

MQP-B-20172 (PrNd Based) 120C

MQP-B-20052 (Nd Based) 150C

MQP-B-20172 (PrNd Based) 150C


REFeB Magnets with Cerium Lower cost, Stable Price MQP Range

Cerium / Lanthanum Based MQP

• Rare earths like Ce or La is relatively more abundant in rare earth sources

– Demand for cerium and lanthanum is less than for “magnetic rare earths”

• These materials should have more stable pricing compared to Nd and Pr

– Less fluctuation of raw material prices

• Ce and La should have lower long-term prices

Cost/Performance Trade-off

• When the amount of Ce/La increases, price and performance decreases – Ideal for magnets of middle or lower magnetic

properties – In order to take advantage of the Ce/La cost, it will be

beneficial to consider magnets of middle or lower magnetic properties when designing motor/sensor applications

Low cost, Stable price Portfolio: Products can be tailored within wide range of properties

Ce15

Ce20 Ce30

Ce60

MQP-12.5-8.5

550

600

650

700

750

800

850

900

300 400 500 600 700 800 900

Br (

mT)

Hci (kA/m)

5%

80%

40%

80%

% of Ce/La indicated (relative to TRE)

Ce-Based Powders

Ce Content

Powder Magnet (PC=2 magnet) Br

(mT) Hci

(kA/m) (BH)max (kJ/m3)

Br (kGs)

Hci (kOe)

(BH)max (MGOe)

0% 873 869 123 6.92 10.29 9.13 5% 857 838 117 6.80 9.91 8.80

10% 843 851 114 6.69 10.00 8.50 MQP-13-9-20143

(15%) 829 777 107 6.58 9.13 8.10 20% 815 709.5 101 6.51 8.51 7.82 30% 800 661 97 6.39 7.91 7.45 40% 769 580 85 6.22 6.88 6.83 50% 751 549 81 6.08 6.51 6.50 60% 718 483 71 5.84 5.71 5.80

MQP-8-5-20159 (80%) 671 411 63 5.43 5.03 5.42

MQP-7-8-20171 (80%) 599 663 54 4.74 7.84 4.11

Example: MQP-7-8 and MQP-8-5 (Cerium 80%) Same low cost RE%, but different properties tailored to different customer requirements

Powder Properties Magnet Properties Br

(kG) Hci


Springback (%)

Br (kG)

Hci


MQP-7-8-20171

6.0 8.3 6.8 0.86% 4.7 7.8 4.1

MQP-8-5-20159

6.7 5.2 7.9 0.73% 5.4 5.0 5.4

0

2

4

6

8

-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0

B-H

(kG

)

H (kOe)

Powder

MQP 8-5-20159MQP 7-8-20171

0

2

4

6

8

-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0

B-H

(kG

)

H (kOe)

Magnet

MQP 8-5-20159MQP 7-8-20171

0,0

1,0

2,0

3,0

4,0

5,0

6,0

7,0

8,0

Mag

net B

r (kG

)

Ce Content (% TRE)

Br Vs Ce Content

Aging Loss: 120oC

-16

-14

-12

-10

-8

-6

-4

-2

0

0 100 200 300 400 500 600

Agi

ng L

oss

(%)

Test Time (hours)

120℃ Aging Loss Chart Ce0

Ce5

Ce10

Ce15

Ce20

Ce30

Ce40

Ce50

Ce60

13-9-20063

MQP-7-8

MQP-8-5

B/µoH=-2

Case Study # 1: Seat Motor

Case Study # 1: Seat Motor Reversed Engineering of the Benchmarked Motor

Case Study # 1: Seat Motor Design Comparison of the Benchmarked and Redesigned Motors

Parameter Benchmark PMDC Motor

4-Pole PMDC motor with Isotropic Bonded Neo Magnets

Type of Magnet Ferrite MQP B+-20056-070 MQP-10-8.5HD Total motor weight (gm) 368.64 214.84 253.42

Length of the motor* (mm) 43.00 33.20 34.00

Overall diameter**(mm) 48.60 36.52 40.22

Overall Width (mm) 44.25 36.52 40.22

Total copper weight (gm) 59.73 34.50 39.80

Total magnet weight (gm) 101.86 18.44 27.33

Length of Air gap (mm) 0.51 0.51 0.51 Current at 150 mN-m (A) 5.78 5.75 5.8531 Current at 300 mN-m (A) 10.60 10.58 10.73

Efficiency at 150 mN-m (%) 60.25 61.82 62.28 Efficiency at 300 mN-m (%) 46.50 50.16 52.21

Case Study # 1: Seat Motor Characteristics for the Benchmarked and Redesigned Motors

Torque-Speed and Torque-Current Characteristics for the Benchmarked 2-pole Ferrite and Redesigned 4-pole Isotropic Bonded Neo Magnet Motors

Torque-Efficiency and Torque-Power Characteristics for the Benchmarked

2-Pole Ferrite and Redesigned 4-Pole Isotropic Bonded Neo Magnet

Motors

Case Study # 1: Seat Motor Comparison of the Benchmarked and Redesigned Motors

Benchmarked Motor Redesigned Motor using

MQP-B+-20056-070

Redesigned Motor using

MQP-10-8.5

Case Study # 1: Seat Motor Comparison of Physical Parameters for Benchmarked and Redesigned Motors

Case Study # 2: Window Lift Motor

Case Study # 2: Window Lift Motor Design Comparison of the Benchmarked and Redesigned Motors

Parameter Benchmark PMDC Motor

4-Pole PMDC motor with Isotropic Bonded Neo Magnets

Type of Magnet Ferrite MQP B+-20056-070 MQP-10-8.5HD Total motor weight (gm) 245.00 108.85 169.19

Length of the motor* (mm) 38.00 30.00 30.00

Overall diameter**(mm) 42.20 30.60 32.60

Overall Width (mm) 32.60 30.60 32.60



Length of Air gap (mm) 0.45 0.50 0.50 Current at 50 mN-m (A) 3.80 3.15 3.36

Current at 100 mN-m (A) 6.35 5.44 5.75 Efficiency at 50 mN-m (%) 49.00 60.80 59.36

Efficiency at 100 mN-m (%) 41.12 59.04 57.93

Case Study # 2: Window Lift Motor Characteristics for the Benchmarked and Redesigned Motors

Torque-Speed and Torque-Current Characteristics for the Benchmarked 2-pole Ferrite and Redesigned 4-pole Isotropic Bonded Neo Magnet Motors

Torque-Efficiency and Torque-Power Characteristics for the Benchmarked

2-Pole Ferrite and Redesigned 4-Pole Isotropic Bonded Neo Magnet

Motors

Case Study # 2: Window Lift Motor Comparison of the Benchmarked and Redesigned Motors

Redesigned Motor using

MQP-10-8.5

Benchmarked Motor Redesigned Motor using

MQP-B+-20056-070

Case Study # 2: Window Lift Motor Comparison of the Physical Parameters for Benchmarked and Redesigned Motors

Escalating Price of Dy: Fundamental supply-demand imbalance

High demand in Dy rich sintered neo applications Low output

*Source:National Development and Reform Commission (NDRC) Report April 2011

Estimated Production in 2010*

Lanthanum24.6%

Cerium29.0%Praseodymium

5.4%

Neodymium20.7%

Samarium2.0%

Europium1.0%

Gadolinium1.6%

Terbium0.6%

Dysprosium2.4%

Erbium1.1%

Yttrium11.7%

MQ3 Magnets from Daido

49


Case Study Motor in Power Tool

Substitution of Sintered NdFeB Magnets

HVAC Blower (Dy free)

58

Rotors designed for case study

Sintered Neo (35SH) Sintered Neo (N35)

Bonded Neo Motor

Dy free 3% Dy

Dy free

Comparison of Mechanical Parameters

59

Parameter 4-Pole PMDC Motor Sintered Neo

4-Pole PMDC Motor Sintered Neo

4-Pole PMDC Motor Bonded Neo

Type of Magnet 4-Arc Sintered neo (N35SH)

4-Arc Sintered Neo (N35)

Isotropic Ring Bonded Neo (MQP-B+)

Dy content ~3% 0-0.5% 0%

Total motor weight (g) 314.90 451.4 412.50

Length of the motor /mm 18.00 23.00 20.00

Overall diameter (mm) 57.50 60.72 63.90



Length of Air gap (mm) 0.55 0.55 0.55

Current at 220 mN-m (A) 11.08 10.55 11.21

Efficiency @ 220 mN-m % 73.76 74.59 74.09

Table 5: Comparison of Sintered and Bonded Neo Based Motors.

Torque Efficiency and -Power

Comparison Of Properties and Cost

61


MQ 3 Full Dense Anisotropic Magnets


63

Effect of Substituting Pr for Nd

0

0.2

0.4

0.6

0.8

1

1.2

1.4

-1800 -1600 -1400 -1200 -1000 -800 -600 -400 -200 0

H (kA/m)

B-H

(T)

Pr-Fe-B-Cu at 25degC Pr-Fe-B-Cu at 100degC Pr-Fe-B-Cu at 180degC

(Nd,Pr)-Fe-B-Cu 25degC (Nd,Pr)-Fe-B-Cu 100degC (Nd,Pr)-Fe-B-Cu at 180degC

When comparing PrFeBCu and (¾Nd¼Pr)FeBCu MQ3 magnets, higher Pr causes a greater decrease in Hci over a temperature range due to a larger thermal coefficient of Hci (-β %/oC)

Substituting Pr for Nd in Nd2Fe14B magnets increases the room temperature Hci and reduces the grain boundary phase melting temperature to improve hot deformability. However Pr based magnets lose more Hci at elevated temperatures than Nd based magnets.

25oC

180oC 100oC

MQ3 Magnets

• There is a trade off between Br and Hci with NdFeB MQU powders.

• For high Br the grain-alignment must be maximized and RE decreased to the point where workability is just possible (~29 wt% TRE).

• Pr shows an impressive impact on HcJ; 1600 kA/m with no Dy is a target.

• High Hci (>1600 kA/m) requires Dy or Tb.

• The fine nano-scale of MQ3 microstructures give these magnets an advantage in terms of Dy-dependence relative to sintered magnets.

• There is a difference of about 3 wt.-% Dy between sintered and full dense MQ3 in comparison at the same coercivity.


66

Actual Material

In an actual study it is approved for production material to reach a remanence of 1240 mT and a coercivity of 1600 kA/m without Dy. By variations of process parameters higher flux values at the expense of a reduction of the coercivity are possible.

Summary

Bonded Magnets based on Rapid Quenching can be designed by composition by the quenching process

The main driving force today for new developments in the field of Bonded Magnets is cost reduction Nd can be substituted by Pr without compromises in magnetic

performance Nd can be substituted by low cost RE materials like Ce and La if lower

performance in the materials is acceptable The ratio „flux/cost“ with La or Ce can be better than with Nd or Pr

Market demand for MQ3 due to lower Dy (cost, strategic) High coercivities by Pr additions High coercivities by improved microstructure, 3wt.-% difference to sintered

Cost Effective Materials Based on NdFeB Compounds · Cost Effective Materials Based on NdFeB...

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