Magnetics 2013
Dysprosium-free rare earth magnets
Orlando, February 6-8
Presenter: Jim Herchenroeder
Vice President
Vision and Values
VISION
To be the world class Rare Earth products and
technology company recognized for its ETHICS
Our VALUES: ETHICS
Excellence, Trust, Honesty, Integrity, Creativity and
Safety
2
Outline
• Hot pressed fully dense Dy-free MQ2 magnets
– Introduction
– Grain size advantage of MQ2
– Case study: 4-pole PMDC Motor
• Isotropic bonded MQ1 magnets
– High flux MQ1 magnets
3
DY-FREE MQ2
HOT PRESSED FULLY DENSE MAGNETS
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Manufacturing Process
Jet Casting
MQ2 Magnet Cold Press
MQ2 Magnet Hot Press
Cold pressed
magnet insertion
stage
Magnet pressing
stage
Unloading of hot
pressed magnet
Grind to Tolerance
Coating
Permanent Magnet Materials:
Magnet Curves
1.4
1.2
1.0
0.8
MQ3
Sintered Neo
(43SH)
MQ2
J(T)
SmCo
0.6
0.4
MQA-38-14
(Injection
Molded)
Sintered
Ferrite
MQP-16-9HD
0.2
0.0
-2400
-2000
-1600
-1200
H (kA/m)
-800
-400
0
6
Grain size
• MQ2 has smaller grain size which makes high
HcJ possible
– MQ2 makes higher HcJ than sintered Neo at lower Dy
concentration
1 Sintered
Neo Grain
There are 106 MQ2 grains for every
1 sintered Neo grain
Sintered Neo Comparison
• Isotropic MQ2 has naturally lower β
– Sintered Neo uses HRE to lower the temperature
coefficient of HcJ
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Sintered Neo Comparison
•
•
•
•
Higher HcJ (grain size) and lower β (isotropic) combine to give much
better temperature stability than sintered Neo
MQ2 saves 5-7% Dy in the magnet reducing magnet cost
MQ2 is a cost effective solution at temperatures above 125°C
Cost/flux ratio in MQ2 can be reduced by half compared to sintered
Neo because HRE are not needed
Value of MQ2
At high temperatures, MQ2 has a higher value than sintered
neo
Cost per unit of flux
Sintered Neo
MQ2
Operating temperature
10
TEMPERATURE STABILITY
Magnet
25°C
HcB Br
50°C
HcB Br
75°C
HcB Br
100°C
HcB Br
125°C
HcB Br
150°C
HcB Br
175°C
HcB Br
200°C
% Dy
[kOe] [kG] [kOe] [kG] [kOe] [kG] [kOe] [kG] [kOe] [kG] [kOe] [kG] [kOe] [kG]
MQ2-16-125
7.5
8.5
7.2
8.4
7.0
8.2
6.6
7.9
6.2
7.7
5.7
7.3
5.0
7.0
0
MQ2-14-150
7.1
8.0
6.8
7.9
6.6
7.7
6.4
7.5
6.1
7.2
5.7
7.0
5.4
6.7
0
MQ2-14-175
7.2
8.0
6.9
7.8
6.7
7.6
6.4
7.4
6.1
7.2
5.7
6.9
5.3
6.6
0
MQ2-13-200
6.9
7.7
6.7
7.6
6.5
7.4
6.3
7.2
6.0
7.0
5.7
6.7
5.4
6.5
2.5
H (kOe)
• MQ2 has good stability
up to 175°C without Dy
B (kG)
8
-10
-7.5
-5
-2.5
0
1.0
MQ2-13-200
MQ2-14-150
MQ2-14-175
MQ2-16-125
0.8
125oC
150oC
6
0.6
175oC
4
0.4
175oC
0.2
2
0
-1000
J (T)
-12.5
10
0.0
-800
Straight line B-H curve at respective temperature
-600
-400
H (kA/m)
-200
0
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Temperature stability for high temperature
applications
Electric Vehicle Motors
Engine Cooling Fans
AC Compressors
Under-the-hood
Applications
Irreversible Flux Loss (%)
0.0
-1.0
-2.0
-3.0
-4.0
MQ2-14-150
MQ2-14-175
MQ2-13-200
-5.0
0 100 200 300 400 500 600 700 800 9001000
Time (hours)
@200oC
MQ2 magnets (PC=2)
retain 98% flux after
1000 hours at 200oC
without dysprosium
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Corrosion
•
•
Magnet Type
Initial
Mass
(g)
Final
Mass
(g)
Loss
(%)
35H
35SH
35UH
MQ2-16-125
MQ2-14-150
MQ2-14-175
MQ2-13-200
5.02
5.03
5.10
18.22
18.25
18.10
18.14
4.97
4.98
5.08
18.21
18.25
18.09
18.14
-0.98%
-0.86%
-0.39%
-0.02%
-0.01%
-0.04%
-0.01%
Surface
Loss
Area (cm2) (mg/cm2)
4.30
4.29
4.29
8.51
8.58
8.58
8.48
-11.43
-10.108
-4.64
-0.47
-0.15
-0.77
-0.21
Sintered neo magnets
show 10-50 times the
corrosion as MQ2
85%RH/85°C for 4 weeks
MQ2-14-150
N35SH
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Case Study:
4-pole PMDC Motor
• To illustrate the technical and economic benefits of
utilizing bonded neo as compared to sintered neo
Benchmarked 4-pole PMDC Motor
with Sintered Neo (4% Dy)
Dy-free MQ2
Electromagnetic Design
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Case Study: 4-pole PMDC Motor
Benchmarked and Redesign Motor Comparison
Parameter
Benchmarked
Redesigned
Type of Magnet
4-Pole, Sintered Neo
(N27 SH/N30SH)
4-Pole, MQ2-14-150
(8-Arcs)
Dy (%)
4.14
0
Overall diameter of the motor (mm)
44.10
44.10
Length of the motor (mm)
15.50
16.50
Length of airgap (mm)
0.57
0.57
Total copper weight (gm)
28.09
33.60
Total magnet weight (gm)
18.47
26.00
Total motor weight (gm)
151.35
168.10
Current at 80 mN-m (A)
14.76
14.05
Efficiency at 80 mN-m (%)
64.15
64.92
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Case Study: 4-pole PMDC Motor
Benchmarked and Redesigned Motor Performance
Torque-efficiency and torque-output
power characteristics
Torque-speed and torque-current
characteristics
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Case Study: 4-pole PMDC Motor
Benchmarked and Redesign Motor Comparison
Benchmarked 4-pole PMDC Motor
with Sintered Neo (4% Dy)
Dy-free MQ2
Electromagnetic Design
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Case Study: 4-pole PMDC Motor
Comparison of the Benchmarked and Redesign
Motors
Sintered Neo magnet N30SH
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MQ2 Summary
• Ideal for applications that require high performance at
elevated temperature.
• MQ2 magnets provide excellent temperature stability
– With no presence of heavy rare earths like Terbium and
Dysprosium.
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HIGH FLUX MQ1
ISOTROPIC BONDED MAGNETS
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About high flux MQ1
• Achieve the highest flux for isotropic bonded
materials
• Utilize high density MQP grades
– Designed specifically to allow for higher compaction
– MQP-16-9HD and MQP-15-9HD (other high density
grades are also available)
• Offer 10-15% higher BHmax than standard MQ1
magnets
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High Flux MQ1
Magnet Performance Comparison – PC=2 Cylinders
Powder
Type
Density
(g/cm3)
6.0
MQEP16-9HD
MQEP15-9HD
OD Height Weight
(mm) (mm)
(g)
9.792 6.45 2.920
Br
(kGs)
7.03
Hc
(kOe)
5.81
Hci
(kOe)
8.92
BH(max)
(MGOe)
10.28
6.4
9.813
6.45
3.139
7.59
6.11
8.81
11.72
6.0
9.800
6.45
2.916
6.97
5.74
9.28
10.04
6.4
9.831
6.45
3.140
7.52
6.04
9.14
11.35
8
•
7
6
16-9HD-6.0g/cc
4
16-9HD-6.4g/cc
15-9HD-6.0g/cc
3
15-9HD-6.4g/cc
2
1
0
-10
-9
-8
-7
-6
-5
-4
H (kOe)
-3
-2
-1
0
B/J (kGs)
5
•
•
BHmax increased by 1314% from 6.0g/cm3 to
6.4g/cm3, tested by
standard cylinder magnet
of PC=2
Similar results by 15-9HD
and 16-9HD
Proprietary pressing
techniques to achieve
6.4g/cm3 compact density'
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High Flux MQ1
Visual Appearance
• Ring magnet for automotive seat motor
[Φ33.7 x Φ30.7 x H25.4mm]
Commercially Available
MQP-B+ (5.9g/cc)
Magnequench MQP-169HD (6.4g/cc)
High Flux MQ1 Case Study
• Flux per pole improve by 13.6%
MQP-16-9HD
@6.4g/cc
MQP-B+
@5.9g/cc
Flux/pole (mWb)
58.85
51.77
Speed = 500 RPM
Back-emf constant (mV/rpm)
3.717
3.427
Speed = 2000 RPM
Back-emf constant (mV/rpm)
3.717
3.404
Speed = 2500 RPM
Back-emf constant (mV/rpm)
3.727
3.412
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Magnet
Peak Efficiency (%)
MQP-16-9HD
@ 6.4g/cc
50.63
Torque-Speed & Torque-Current
MQP-B+
@ 5.9g/cc
47.64
High Flux MQ1
Motor Performance
Torque-Power & Torque-Efficiency
MQ1 magnets at 6.4g/cc density offer performance that is comparable to commercially
available HDDR magnets.
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DISCUSSION
QUESTIONS?
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