Recently, the energy product of bulk nanocomposite Nd2Fe14B/Fe magnets has reached 50 MGOe, a level that can compete with the best conventional Nd-Fe-B magnets. With continued development, much higher energy densities (up to 90 MGOe) are anticipated. This new development represents a great opportunity for significantly improving performance, enhancing energy efficiency, and reducing volume and weight of advanced electromagnetic machines, including permanent magnet generators and motors. This project will develop innovative technologies and cost-effective manufacturing processes for synthesizing high-energy-density nanocomposite magnets with energy products greater than 60 MGOe, which will be a breakthrough in magnetic performance over all known materials. In addition to much higher magnetic performance, the new magnets will have (1) lower cost as a result of reduced rare earth content; (2) improved corrosion resistance; and (3) improved fracture toughness owing to an ultra-fine grain structure. Phase I will study and optimize two innovative processes, rapid inductive compaction and hot deformation. Then the feasibility of enhancing magnetization by forming near-perfect nanograin alignment and increasing the amount of the magnetically soft phase will be determined. Finally, the feasibility of increasing coercivity by controlling the nanostructure, especially by reducing the size of the magnetically soft phase and improving its distribution, will be demonstrated.
Commercial Applications and Other Benefits as described by the awardee: This new type of hybrid nanomagnets should lay the foundation for future fourth generation rare earth magnets that will have magnetic performance at least 50% higher than the current third generation Nd-Fe-B magnets. Applications for these new magnets are expected to include hybrid electric automobiles and future all-electric fuel cell powered automobiles, as well as numerous electromagnetic devices and machines such as generators, motors, actuators, accelerators, klystrons, gyros, and microwave devices
