Extrusion compression molded critical rare earth free bonded permanent magnets

Mariappan Parans Paranthaman; Harshida Parmar; Kaustubh Mungale; James W. Kemp; Haobo Wang; Ikenna C. Nlebedim; Uday Kumar Vaidya

doi:10.1016/j.mtla.2025.102359

Extrusion compression molded critical rare earth free bonded permanent magnets

Mariappan Parans Paranthaman
, Harshida Parmar
, Kaustubh Mungale
, James W. Kemp
, Haobo Wang
, Ikenna C. Nlebedim
, Uday Kumar Vaidya

Nanomaterials Chemistry Group

Research output: Contribution to journal › Article › peer-review

1 Scopus citations

Abstract

Samarium iron nitride (Sm-Fe-N) bonded magnets have emerged as promising candidates for various industrial applications due to their exceptional magnetic properties. Compounds with magnetic material 95 wt fraction (wt.%) (∼74 vol%) and 97 wt.% (∼81 vol%) of SmFeN in a polyamide (PA12) polymer binder are manufactured using a batch mixer followed by compression molding. A maximum energy product (BH)_max of 186.21 kJ.m^-3 (23.4 MGOe) is achieved in the 95 wt.% bonded magnets; 97 wt.% magnets had a (BH)_max of 165.52 kJ.m^-3 (20.8 MGOe). It is found that the degree of alignment (DoA) of 99 % is achieved in the 95 wt.% magnets, whereas the 97 wt.% magnets are limited to a DoA of 90 % respectively. The high DoA can be attributed to low particle-particle interaction during the post-magnetic field alignment process. This research provides a useful insight of binder-particle interactions at very high magnet weight fractions and their effect on magnetic strength and performance.

Original language	English
Article number	102359
Journal	Materialia
Volume	39
DOIs	https://doi.org/10.1016/j.mtla.2025.102359
State	Published - Mar 2025

Funding

This research was supported by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Wind Energy Technologies Office Program. Part of the magnetic fabrication and characterization research was supported by the Critical Materials Innovation, an Energy Innovation Hub funded by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing and Manufacturing Technologies Office. Scanning Electron Microscopy (SEM) microstructural characterizations were conducted a part of a user project at the Center for Nanophase Materials Sciences(CNMS), which is a US Department of Energy Office of Science User Facility at Oak Ridge National Laboratory. Thanks are due to Professor Brett G. Compson for the use of his hardness tester equipment. This manuscript has been authored in part by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan). This research was supported by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Wind Energy Technologies Office Program. Part of the magnetic fabrication and characterization research was supported by the Critical Materials Innovation, an Energy Innovation Hub funded by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing and Manufacturing Technologies Office. Scanning Electron Microscopy (SEM) microstructural characterizations were conducted a part of a user project at the Center for Nanophase Materials Sciences(CNMS), which is a US Department of Energy Office of Science User Facility at Oak Ridge National Laboratory.

Keywords

Bonded magnets
Critical rare earth free magnets
Extrusion compression molding
Magnetic properties
Sm-Fe-N

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10.1016/j.mtla.2025.102359

Cite this

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title = "Extrusion compression molded critical rare earth free bonded permanent magnets",

abstract = "Samarium iron nitride (Sm-Fe-N) bonded magnets have emerged as promising candidates for various industrial applications due to their exceptional magnetic properties. Compounds with magnetic material 95 wt fraction (wt.\%) (∼74 vol\%) and 97 wt.\% (∼81 vol\%) of SmFeN in a polyamide (PA12) polymer binder are manufactured using a batch mixer followed by compression molding. A maximum energy product (BH)max of 186.21 kJ.m-3 (23.4 MGOe) is achieved in the 95 wt.\% bonded magnets; 97 wt.\% magnets had a (BH)max of 165.52 kJ.m-3 (20.8 MGOe). It is found that the degree of alignment (DoA) of 99 \% is achieved in the 95 wt.\% magnets, whereas the 97 wt.\% magnets are limited to a DoA of 90 \% respectively. The high DoA can be attributed to low particle-particle interaction during the post-magnetic field alignment process. This research provides a useful insight of binder-particle interactions at very high magnet weight fractions and their effect on magnetic strength and performance.",

keywords = "Bonded magnets, Critical rare earth free magnets, Extrusion compression molding, Magnetic properties, Sm-Fe-N",

author = "Paranthaman, \{Mariappan Parans\} and Harshida Parmar and Kaustubh Mungale and Kemp, \{James W.\} and Haobo Wang and Nlebedim, \{Ikenna C.\} and Vaidya, \{Uday Kumar\}",

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year = "2025",

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doi = "10.1016/j.mtla.2025.102359",

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AU - Paranthaman, Mariappan Parans

AU - Parmar, Harshida

AU - Mungale, Kaustubh

AU - Kemp, James W.

AU - Wang, Haobo

AU - Nlebedim, Ikenna C.

AU - Vaidya, Uday Kumar

PY - 2025/3

Y1 - 2025/3

N2 - Samarium iron nitride (Sm-Fe-N) bonded magnets have emerged as promising candidates for various industrial applications due to their exceptional magnetic properties. Compounds with magnetic material 95 wt fraction (wt.%) (∼74 vol%) and 97 wt.% (∼81 vol%) of SmFeN in a polyamide (PA12) polymer binder are manufactured using a batch mixer followed by compression molding. A maximum energy product (BH)max of 186.21 kJ.m-3 (23.4 MGOe) is achieved in the 95 wt.% bonded magnets; 97 wt.% magnets had a (BH)max of 165.52 kJ.m-3 (20.8 MGOe). It is found that the degree of alignment (DoA) of 99 % is achieved in the 95 wt.% magnets, whereas the 97 wt.% magnets are limited to a DoA of 90 % respectively. The high DoA can be attributed to low particle-particle interaction during the post-magnetic field alignment process. This research provides a useful insight of binder-particle interactions at very high magnet weight fractions and their effect on magnetic strength and performance.

AB - Samarium iron nitride (Sm-Fe-N) bonded magnets have emerged as promising candidates for various industrial applications due to their exceptional magnetic properties. Compounds with magnetic material 95 wt fraction (wt.%) (∼74 vol%) and 97 wt.% (∼81 vol%) of SmFeN in a polyamide (PA12) polymer binder are manufactured using a batch mixer followed by compression molding. A maximum energy product (BH)max of 186.21 kJ.m-3 (23.4 MGOe) is achieved in the 95 wt.% bonded magnets; 97 wt.% magnets had a (BH)max of 165.52 kJ.m-3 (20.8 MGOe). It is found that the degree of alignment (DoA) of 99 % is achieved in the 95 wt.% magnets, whereas the 97 wt.% magnets are limited to a DoA of 90 % respectively. The high DoA can be attributed to low particle-particle interaction during the post-magnetic field alignment process. This research provides a useful insight of binder-particle interactions at very high magnet weight fractions and their effect on magnetic strength and performance.

KW - Bonded magnets

KW - Critical rare earth free magnets

KW - Extrusion compression molding

KW - Magnetic properties

KW - Sm-Fe-N

UR - https://www.scopus.com/pages/publications/85217053041

U2 - 10.1016/j.mtla.2025.102359

DO - 10.1016/j.mtla.2025.102359

M3 - Article

AN - SCOPUS:85217053041

SN - 2589-1529

VL - 39

JO - Materialia

JF - Materialia

M1 - 102359

ER -

Extrusion compression molded critical rare earth free bonded permanent magnets

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Keywords

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