09.11.2017

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Tailored Metal Injection MouldingOf Isotropic NdFeB Hard Magnets

Based On Recycled Powders

Prof. Dr. Carlo Burkhardt

Workshop in the frame of the WorldResources Forum – 25 October 2017Info Session

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

1) Prof. Dr. Ralf Wehrspohn, Kritikalität Seltener Erden, Fraunhofer Industrieworkshop „Magnetwerkstoffe“ ,Bremen, 19.05.20152) F. Meyer, Recycling von Nd aus Nd-Fe-B Magneten in Elektroaltgeräten, HS Hamburg, 16.04.20123) M. Buchert, Untersuchungen zu seltenen Erden: Permanentmagnete im industriellen Einsatz in Baden-Württemberg, Stuttgart,13.11.2013

For recycling potentially available Nd-Fe-B-magnets(Germany alone):

• Computer/Laptops > 60t/a (~10g/item)1)

• Passenger cars (ICE) > 450 t/a (~1 kg/car)2)

• Industrial electric motors > 30 t/a (0,05–2 kg/item)3)

> 500 t/a

Outlook:Recycling quantities currently negligible, but relevant forthe future (~5-20 years):

• Hybrid cars > 10 kg/car• Electric cars > 30 kg/car• Wind turbines > 600 kg/MW

100% waste-free production of complexely shaped Rare-Earth mag-nets (Nd-Fe-B) using recycled magnets in a closed material loop

Workshop in the frame of the WorldResources Forum – 25 October 2017ReProMag

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

09.11.2017

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What is REProMag?

Processing Parameters

Results

Summary and Outlook

Workshop in the frame of the WorldResources Forum – 25 October 2017Introduction

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

Duration: 1.1.2015 – 31.12.2017Funded Budget: 5,7 Mio €uro

14 Partners from 5 European Countries

OBE Ohnmacht & BaumgärtnerGmbH & Co. KG, Ispringen (D)

University of Birmingham (GB)Technische Universität Wien (A)Montanuniversität Leoben (A)Institut Jozef Stefan Ljubljana (SLO)National Physics Laboratory Sheffield (GB)

FOTEC GmbH, Wiener Neustadt (A)Pt+A GmbH, Dresden (D)Hage GmbH, Obdach (A)Lithoz, Wien (A)TEKS s.a.r.l., Montgenèvre (F)

Siemens A.G., München (D)Sennheiser GmbH & Co. KG, Wedemark (D)

Steinbeis Europa-Zentrum, Karlsruhe (D)

Workshop in the frame of the WorldResources Forum – 25 October 2017Introduction

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

09.11.2017

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HD (hydrogen decrepitation) process

Workshop in the frame of the WorldResources Forum – 25 October 2017The SDS process

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

HD (hydrogen decrepitation) process

(1) MIM(metal injection

moulding)

(2) FFF(fused filamentfabrication)

(3) LAM(lithography-basedadditivemanufacturing)

Workshop in the frame of the WorldResources Forum – 25 October 2017

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

The SDS process

09.11.2017

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HD (hydrogen decrepitation) process

(1) MIM(metal injection

moulding)

(2) FFF(fused filamentfabrication)

(3) LAM(lithography-basedadditivemanufacturing)

Workshop in the frame of the WorldResources Forum – 25 October 2017

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

The SDS process

HD (hydrogen decrepitation) process

(1) MIM(metal injection

moulding)

(2) FFF(fused filamentfabrication)

(3) LAM(lithography-basedadditivemanufacturing)h

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Workshop in the frame of the WorldResources Forum – 25 October 2017

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

The SDS process

09.11.2017

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HD (hydrogen decrepitation) process

(1) MIM(metal injection

moulding)

(2) FFF(fused filamentfabrication)

(3) LAM(lithography-basedadditivemanufacturing)

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Workshop in the frame of the WorldResources Forum – 25 October 2017

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

The SDS process

What is REProMag?

Processing Parameters

Results

Summary and Outlook

Workshop in the frame of the WorldResources Forum – 25 October 2017SDS-Processing

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

09.11.2017

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Powder Binder Handling Alignment Heat Treatment

+ NdH2Nd Dy Pr Fe Co B Cu Nb Al

wt% 27.3 4.42 0.35 61.1 4.44 1.05 0.04 0.87 0.36

Workshop in the frame of the WorldResources Forum – 25 October 2017

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

SDS processing

POLAR UNPOLAR

Powder Binder Handling Alignment Heat Treatment

Hydrogen atom

Carbon atom

Oxygen atomO. Weber, Dissertation, Universität Freiburg, 2015

Workshop in the frame of the WorldResources Forum – 25 October 2017

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

SDS processing

09.11.2017

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expensive

Powder treatment

Compounding

Shaping

Ar

air Ar Ar

air air Ar

cheap

Powder Binder Handling Alignment Heat Treatments

Workshop in the frame of the WorldResources Forum – 25 October 2017

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

SDS processing

(0,6-0,8) T

Powder Binder Handling Alignment Heat Treatments

Workshop in the frame of the WorldResources Forum – 25 October 2017

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

SDS processing

09.11.2017

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time

tem

pe

ratu

re

thermaldebinding

sintering

Powder Binder Handling Alignment Heat Treatments

− Sinteringtemperature

− Sintering time− Atmosphere− Sintering trays

− Kinetics− Atmosphere

C. Burkhardt, Metallpulverspritzguss –Fertigung komplexer Bauteile in höchsterPräzision, 2013

Workshop in the frame of the WorldResources Forum – 25 October 2017

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

SDS processing

< 1,0 wt.% < 0,1 wt.%

source: “MIM magnets in the REEgainproject”, DTU

Powder Binder Handling Alignment Heat Treatments

Workshop in the frame of the WorldResources Forum – 25 October 2017

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

SDS processing

09.11.2017

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binder decomposition powder dehydration

Powder Binder Handling Alignment Heat Treatments

Workshop in the frame of the WorldResources Forum – 25 October 2017

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

SDS processing

What is REProMag?

Processing Parameters

Results

Summary and Outlook

Workshop in the frame of the WorldResources Forum – 25 October 2017Results

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

09.11.2017

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Oxygen content (wt.%)

Hci

(kA

/m)

Carbon content (wt.%)

Hci

(kA

/m)

Hci intrinsic coercivity (kA/m) as a function of oxygen and carbon content

Workshop in the frame of the WorldResources Forum – 25 October 2017Results

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

ρ = 7,3 g/cm³

ρ = 6,9 g/cm³

ρ = 6,3 g/cm³

ρ = 7,4 g/cm³

Br: 644 mTHcj: 1061kA/m

polar binder

unpolar binder

protectiveatmosphere

alignment

heat treatment

Br: 603 mTHcj: 1296kA/m

Workshop in the frame of the WorldResources Forum – 25 October 2017Results

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

09.11.2017

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Material characterisation of isotropic SDS magnets (no alignment in tooling)

Nd Dy Pr Fe Co B Cu Nb Al

wt% 27.3 4.42 0.35 61.1 4.44 1.05 0.04 0.87 0.36

Scrap magnets before HD process MIM magnets after SDS process

Nd2Fe14B-matrix

Nd-rich

Workshop in the frame of the WorldResources Forum – 25 October 2017

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

Results

Material characterisation of isotropic SDS magnets (no alignment in tooling)

„under“sintered microstructure

Nd2Fe14B-matrix

Nd-rich

Workshop in the frame of the WorldResources Forum – 25 October 2017Results

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

09.11.2017

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„over“sintered microstructure

Nd2Fe14B-matrix

Nd-rich

Free Fe

Workshop in the frame of the WorldResources Forum – 25 October 2017Results

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

Material characterisation of isotropic SDS magnets (no alignment in tooling)

optimised microstructure, Nd-additions help to increase density

Nd2Fe14B-matrix

Darker Nd-richBrighter Nd-rich

Workshop in the frame of the WorldResources Forum – 25 October 2017Results

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

Material characterisation of isotropic SDS magnets (no alignment in tooling)

09.11.2017

13

What is REProMag?

Processing Parameters

Results

Summary and Outlook

Workshop in the frame of the WorldResources Forum – 25 October 2017Outlook

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

Processing parameters optimised for„coarse“ recycling powders (HDD)

Results for jet-milled powders in progress

Results for powders with Nd-additions inprogress

Feedstock developmentsuccessful completed

Feedstock develop-ment in progress

Alignment in tooling inprogress

starting magnets (sintered)Hci ~ 1350 kA/m

recycled SDS magnetsHci ~ 1300 kA/m

Hci ~96% of starting values

Fine-Tuning of processing para-meters for other powder sources

Upscaling for serialproduction

Follow-up projectssubmitted

Workshop in the frame of the WorldResources Forum – 25 October 2017

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

http://repromag-project.eu/

Outlook

09.11.2017

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Thank you

Project funded by the European Union’s Horizon 2020 researchand innovation programme under the Grant Agreement n°636881

http://repromag-project.eu/

Workshop in the frame of the WorldResources Forum – 25 October 2017Contact

Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881

OBE Ohnmacht & BaumgärtnerGmbh & Co. KGTurnstrasse 22

75228 Ispringen/Germany+49 7231 802 215

cburkhardt@obe.de

www.repromag-project.eu

http://repromag-project.eu/

Prof. Dr. Carlo Burkhardt