A Simple Process to Manufacture Grain Aligned Permanent Magnets

52 A Simple Process to Manufacture Grain Aligned Permanent Magnets--Advanced Materials Corporation, 700 Technology Drive, P.O. Box 2950, Pittsburgh, PA 15230-2950; (412) 268-5649 Mr. Vijay K. Chandhok, Principal Investigator Dr. S.G. Sankar, Business Official DOE Grant No. DE-FG02-97ER82313 Amount: $74,840 Electromechanical devices that incorporate permanent magnets are inherently superior in energy efficiency because, unlike electromagnets, they provide magnetomotive force without any energy dissipation. In the past, the application of permanent magnets was limited to very small devices, such as subfractional horsepower motors. Traditional methods to manufacture magnets also require many processing steps: pulverizing, milling, magnetic alignment of the grains, cold compacting followed by sintering, and post-sintering. Recent rapid advancement in permanent magnet technology has drastically changed this situation. In Phase I of this project, economic methods to produce grain-oriented neodymium-iron-boron magnets employing just a single-step extrusion process will be investigated. Because the alignment of a magnet produced by hot extrusion depends on the shape and dimensions of the extrusion die, the project will also examine shaped dies and the compositions of the alloys. During Phase II, the most promising approach will be selected, and scale-up of the process will begin. An electro-mechanical device, such as a brushless motor, will be designed and constructed during Phase II to determine the advantages of these magnets. Commercial Applications and Other Benefits as described by the awardee: Economically produced high-energy magnets will be extremely beneficial in the construction of inexpensive, high-efficiency brushless motors for applications in industrial drives, home appliances, and electric vehicles. Such magnets will also benefit the downsizing of computer peripherals, such as disk drive actuators.