Research Trands on Rare Earth and Critical Elements in JJpapan · 2011-09-01 · Research Trands on...
Transcript of Research Trands on Rare Earth and Critical Elements in JJpapan · 2011-09-01 · Research Trands on...
Research Trands on Rare Earth and Critical Elements in JapanJ p
K. Hono
N ti l I tit t f M t i l S i (NIMS)National Institute for Materials Science (NIMS)Tsukuba, 305-0047, Japan
Energy Energy use cleaning
Critical Elements for Energy and EnvironmentCritical Elements for Energy and Environmentgy
Generation, conversion, storagegy
Heat, actuation, illumination, informationg
Fuel CellSolar Cell Battery Thermo-El t i
Motor LEDElectronics
CatalystElectric
Motor LED Catalyst
GaAs
PtRh
LiCo Bi Dy Ga
In
AgAuPd
PtAsInCdRu
RhLaCeGd
CoNiR.E.
TeCoSb
NdSmCoB
InLaEuY
PdRhInW
PdRhR.E.
Ru B Y W
Research Institutes and Funding System in Japan
METIMEXT
Ministry of Education, Culture, Sports, and Science and Technology (MEXT)
Ministry of Economy, Trade and Industry (METI)
JST JSPS NEDO
funding agencies funding agency
UniversitiesNIMS AIST
Strategic Research Applied Research
RIKEN
Basic ResearchIndustry
Elements Science and Technology Elements Science and Technology ProjectProject- Designing Material Functions through Fundamental Research on Elements’ Roles -
BackgroundRare earths and other rare metals utilized for electronics automotives
started 2007
Rare earths and other rare metals utilized for electronics, automotives, information technologies, and robotics are facing their price increase and tight supply due to the rapid increase of their consumptions and export policies of producing countriespolicies of producing countries.
Project OutlineE t bli h i th l f iti l l t i t i l tEstablish sciences on the roles of critical elements in materials to use alternative elements
R&D Aspects on Research Subjects1. Alternative materials composed of ubiquitous and nonhazardous elements2 Advanced utilization of functions stemming from strategic elements2. Advanced utilization of functions stemming from strategic elements3. Practical material design for the effective use of strategic elements
3
METI also started Rare Metal Substitution Project in 2007
Why Why DyDy??(Nd,Dy)-Fe-B sintered magnets for HV and EV
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Fe BNd,Dy
Operation temperature: 200C Sales of HV
K1(Dy) >> K1(Nd)
Nd2Fe14B
Nd Fe
Dy
High Performance Anisotropic Nanocomposite Permanent Magnets with Low Rare Earth
Elements Science and TechnologyElements Science and Technology
ContentS. Hirosawa, Hitachi Metals., Ltd., Hitachi Metals, NIMS, Ehime Univ., Kitakyushuu Univ.
A new category of permanent magnet materials with no Dy and less Nd with comparable magnetic properties with those of current (Nd,Dy)-Fe-B sintered magnets using HDDR (Hydrogenation-Decomposition-Desorption-Recombination) and Fe-nanocoating processes.
1400
1600
y (k
A/m
)
Nd-Fe-Co-B-Ga / Nd-CuHydrogenation Desorption
1000
1200
Coe
rciv
ity
Nd-Fe-Co-B-Ga
Nd-Fe-Co-B-Ga ModifiedMicrostructural Analyses and Grain-Boundary ModificationNdH2Nd2Fe14B Nd2Fe14B
HydrogenationDecomposition
DesorptionRecombination
2007 2008 2009 2010 2011Year
Fe
Modification
Search of non-
2
Fe2Bα-Fe
Nd2Fe14B Nd2Fe14BNd-rich Nd-rich
Fe-coated CoercivePowder
Metallic Fe Nano-CoatingProcess
Bulk CompositeMagnet
RapidConsolidationProcess
Fe layer
10 μm10 μm
Concept of the Subjects
aqua coating process on hard-magnetic particles
500nm
Process Process
HDDR particleConcept of the Subjects HDDR particle
Rare Metal Substitute Materials Development Rare Metal Substitute Materials Development ProjectProjectDevelopment of technology for reducing Dy usage in Nd-Fe-B magnets
1. Grain Refinement
2. Interfacial Microstructure Control
(2) Intermetallics (3) TDK(2) Yamagata Univ.
SummaryOperation temperature: 200C
PL: S. Sugimoto, Tohoku U.
1. Grain Refinement
Atomization(Hybrid)
(1) SantokuSC
(2) Intermetallics (3) TDK
He JMFinePowder 55
最終目標ライン(Dy削減30%)
1.0%Dy
30%Dy Saving55
H-HALProcess
5.00 6.00 7.00
(μm
)
Increase in Hc
Dy Saving > 40 %
45
50
0% Dy
MG
Oe)
30
35
40
45
50
(BH)max (MGOe)
基準
中間目標
最終目標
達成値1
達成値2
達成値3基準ライン
中間目標ライン(Dy削減20%)
7%Dy
8%Dy
10%Dy
7.7%Dy(29.6kOe)
y(15.4kOe)
2.4%Dy(18.6kOe)
20%Dy Saving
7%Dy
8%Dy
10%Dy0%Dy Saving
15 20 25 30
50
45
40
35
30
(BH) m
ax(M
GO
e)
10
(1) Tohoku Univ.0.00 1.00 2.00 3.00 4.00
0 50 100 150 200
Gra
in s
ize
Alloy powder size (μm)
~1 m
(3) Tohoku Univ
Dy Saving > 20 %30
40
35
10 20 30Hc(kOe)
10% Dy
20%Saving
30%
50%
(BH) m
ax (
M
Nitrogen JM
Helium JM
10 15 20 25 30HcJ (kOe)
15 20 25 30HcJ (kOe)
10(3) Tohoku Univ.
40
50
60
70
80
90
100
Ndの付着率
(%
)
ℓ = 4 mℓ = 3 mℓ = 2 m
Good
Bad
atio
of
Nd-
rich
, P
(%)
P(%
)
1009080
70605040
Existence ProbabilityIn JM
Improvement of SRNd-rich
(4) Tohoku Univ.600 Nd(f) (3) SIST
CF parameter: Negative
c( )40
0 1 2 3 4 5
Particle size, d50 /um
Ra
, P 0 1 2 3 4 5Particle size, d50 /m
40Powders
(1) Toyota (1) NIMS High HcThick
G.B. -600
-400
-200
0
200
400 Nd(g)
A20 <r2
>
bulk (001) surface model
at surface inside
(3) SIST
Mag. reversal Grp. of grains
4. Application
120
100
80
60
40
20
0
120100806040200
íÖé•
4
3
2
1
0
120
100
80
60
40
20
0
120100806040200
ñ¢íÖé•
Negative
(2) JAEA
3. Guiding Principles
Development of Hot-dipped Aluminum
Elements Science and Technology: Granted in FY2007Elements Science and Technology: Granted in FY2007
Self-forming Nano-particle Catalyst withoutDevelopment of Hot dipped Aluminum Alloy Coated SteelsT. Tsuru, Tokyo Institute of TechnologySubstitution of Zn with Al on Zn coated steel
Self forming Nano particle Catalyst without Precious Metals Y. Nishihata, Japan Atomic Energy Agency
Substantial reduction and/or
Coating Layer
Chemical Properties of Surface
Corrosion resistivity, Sacrificial ability
Metallography and Reactions in Coated Layer
Intermetallic compounds, Solidified structure
oxidation
reduction
total substitution of the precious metals in the automotive catalyst for gasoline engine
Steel Intermetalliccompounds
Thermodynamics of Interfacial Reactions
Interfacial reactions, Wettability Oxidation
Metallography andStrength of Substrate
Mechanical properties,
固溶・析出ナノリサイクル固溶・析出ナノリサイクル
Solution / precipitation
nano recycle
gasoline engine.
Development of New Hot Dipped Coated Steels
Development of New Hot Dipped Coating Process
Wettability, Oxidation p p ,Adhesion, Structure
y
Development of Barium-based New
Development of TiO2-based Transparent ElectrodeT. Hasegawa, Kanagawa Academy of Science p
Lead-free Piezoelectric Materials with Ultrahigh Piezoelectric Property for Piezoelectric FrontierS Wada Yamanashi University ズ①ズ①ズ①ズ①ズ①ズ①D i t l
and Technology
As an ITO (Indium Tin Oxide) alternative, the sputtering-and CVD (Chemical VaporS. Wada, Yamanashi University シーズ①
ドメインエンジニアリング
シーズ①
ドメインエンジニアリング
分域(ドメイン)制御
化
シーズ①
ドメインエンジニアリング
シーズ①
ドメインエンジニアリング
シーズ①
ドメインエンジニアリング
シーズ①
ドメインエンジニアリング
分域(ドメイン)制御
化
Domain control
ned
Ba-based new Pb-free piezoelectric materials with ultrahigh piezoelectric properties
and CVD (Chemical Vapor Deposition) -based practical processes for fabrication of indium-free TNO (niobium-
微細
微細
refin
O (interstitial sites)
ultrahigh piezoelectric properties for future automobile MEMS applications.
(doped titanium dioxide) transparent conducting thin films will be developed.
Nano-hybridized Precious-metal-free
Elements Science and Technology: Granted in FY2008Elements Science and Technology: Granted in FY2008
Material Design and Processing of Highly- Nano-hybridized Precious-metal-free Catalysts for Chemical Energy ConversionK. Uosaki, Hokkaido University
Material Design and Processing of Highly-dispersed Catalysts with Minimum Precious Metal LoadingsM. Machida, Kumamoto University Nano-hybridized precious-metal-freeNano hybridized precious metal free
catalysts for the innovation of fuel cell and photo-electrochemical cell.
Minimizing the loading of precious metals(PGM=Rh, Pt, Pd) and rare earth elements(Ce) in automotive catalysts by realizingthermally stable and highly dispersed PGM
Dissolution& growth
Adsorption of hetero-metal complex to electrode surface
Precipitation of core ions as metal
Development of Innovative Energy Conversion
thermally stable and highly dispersed PGMnano-particles anchored onto support surface.
t l ti PGM C O
(tonnes) 2002 2006PGM: 30 45 X1.5CeO2: 615 1300 X2.1
JPN demands for autocatalysts
e e op e t o o at e e gy Co e s oSystems with Molecular Catalysts Replacing Precious MetalsY. Naruta, Kyushu UniversityDevelopment of molecular catalysts w/o
catalyticconverter
PGM CeO2
Al2O3 supportAl2O3 support
PGM: ~5 g/viecleCe: 17~20 g/viecle
Ubiquitous Element Strategy for Function EmergenceH. Hosono, Tokyo Institute of Technology
Development of molecular catalysts w/o precious metal ions for water decomposition to H2/O2 as well as O2 reduction using organic-inorganic hybrid systems.
Molecular design
Molecular design
Molecular design
Molecular design
Ca
O
Al
Ca
O
Al
Ca
O
Al
Ca
O
Al
g y yNovel functionality based on abundant elements utilizing built-in nanostructures, interface/surface and/or
High
durabilityLow
overpotentialHigh
selectivityHigh electro-motive force
High
durabilityLow
overpotentialHigh
selectivityHigh electro-motive force
electronelectron
C12A7-Electride
Iron -based superconductor
electronelectron
C12A7-Electride
Iron -based superconductor
interface/surface and/or defects.
Design and Processing of Functional Materials with
Elements Science and Technolgoy: Granted in FY2009Elements Science and Technolgoy: Granted in FY2009
Development of Eco-friendly PostDesign and Processing of Functional Materials with Multi-elements Based on Chemical Potential DiagramsT. Uda, Kyoto University
Chemical Potential DiagramChemical Potential Diagram
Development of Eco-friendly Post Lithium-ion BatteriesS. Okada, Kyushu UniversityReplacement of the rare-metal
Th d l t f
LaPOLaPO
Solid ElectrolytesSolid Electrolytes
g+
First principle Calculation
g+
First principle Calculation
・Materials Processing・Chemical Stability・Defect structure・Reaction Mechanism
elements massively used in anode and cathode active materials of lithium-ion battery with economically and ecologically friendly
The development of new phosphate electrolytes for fuel cells, phosphide semiconductorsfor photovoltaic cells, and calcium PO4PO4
Ca
PO4
Ca
PO4 Zn Sn P
Bio MaterialsBio Materials
LaP3O9
LaPO4
Ca5(PO4)3OHPhosphide
SemiconductorsPhosphide
Semiconductors
ZnSnP2
economically and ecologically friendly elements such as sodium and iron.
Opened structure Closed structure
for photovoltaic cells, and calcium hydroxyapatite for bio-materials by computational thermodynamics and the first principle calculations.
Organic Molecular Approach to High-performance Rechargeable Batteries and Mechanistic Elucidation of Charge-discharge Processes
Corner-sharing matrix Edge-sharing matrix Face-sharing matrix
Na 6b siteNa 18e site
Y. Morita, Osaka University
3D NASICON Structure 3D Perovskite Structure 3D Quartz Structure
MO6
octahedra
XO4tetrahedra
Organic molecule high performance rechargeable
3D NASICON Structure 3D Perovskite Structure 3D Quartz Structurebatteries by using the with multi-stage redox ability.
Science and Technology Agency
National National InstiuteInstiute for Materials Science (NIMS)for Materials Science (NIMS)
National Institute for Research in Inorganic Materials (NIRIM)
National Research Institute for Metals (NRIM)
Science and Technology Agency
in Inorganic Materials (NIRIM)(since 1966)
for Metals (NRIM)(since 1956)
Independent Administrative Institution
April 2001 MEXT
National Institute for Materials Science- The only national lab dedicated to materials science in Japan -
1. Fundamental and inovative research on materials science2. Promotion of widespread use of research results and applications3. Shared use of advanced research facilities4 C l i i f h i h i l i di i li4. Cultivation of researchers in the materials science discipline
Budget : $200 million (subsidy from MEXT$150M)Budget : $200 million (subsidy from MEXT$150M)Personnel : 450 researchers, 100 staffs
500 visiting researchers
Where is NIMS ?
Sengen Site Namiki Site
Sakura Site
11
Organization
NanotechnologiesNanotechnologies Nano System Functionality Center Advanced Nano Characterization Center Computational Materials Science Center Quantum Dot Research Center Quantum Beam Center
Advisory Board
AuditorsPresident
Department of Materials Infrastructure
Nanoscale Materials Nanoscale Materials Center Organic Nanomaterials Center Nano Ceramics Center
Quantum Beam Center
Coordinating
Fellows
Vice PresidentsDepartment of Materials Infrastructure High Voltage Electron Microscopy Station High Magnetic Field Station Beam Line Station Materials Data Sheet Station
M t i l D t b St ti
Materials for Information Technology Advanced Electronics Materials Center Optronics Materials Center Magnetic Materials Center
CoordinatingDirectors Materials Database Station
Materials Manufacturing and Engineering Statio Materials Analysis Station
International Center for Materials
Administration OfficesSecretary’s OfficeAudit Office Magnetic Materials Center
Materials for Biotechnology Biomaterials Center
International Center for YoungScientists(ICYS)
International Center for MaterialsNanoArchitectonics(MANA)
Audit OfficeGeneral Affairs DivisionPlanning Division・Integrated Strategy Office・Research Evaluation Office・International Affairs Office
P bli R l ti Offi
Materials for Environment and Energy High Temperature Materials Center Fuel Cell Materials Center
Doctoral Program in MaterialsScience and Engineering
)
NIMS N t h l S t
・Public Relations Office・Human Resources
Development OfficeCollaboration-promotion OfficeScientific Information OfficePlanning & Research Office
Superconducting Materials Center Photocatalytic Materials Center Structural Metals Center
Materials for Reliability and Safety
NIMS Nanotechnology Support Network
Interdisciplinary ClustersSt t i U f S M t i l
gInformation Technology Office
12
y y Material Reliability Center Composites and Coating Center Sensor Materials Center
Strategic Use of Scarce Materials Social Acceptance of Nanotechnology Corrosion Non-Destructive Evaluation
Topics in energy materials at NIMSTopics in energy materials at NIMS
D f
Doping Eu2+ into Si-Al-O-N structureHigh efficiency & durability due to its structure
Point ofResearch
Si-Al-O-N, High efficiency fluorescent material
Analysis and control of nanostructureImproving coercivity of NdFeB w/o Dy
Point ofResearch
Dy-free permanent magnets
Developed Si-Al-O-N materials
High efficiency & durability due to its structureResearch Improving coercivity of NdFeB w/o DyResearch
Nd-based magnet
Cristal structure of α-Si-Al-O-N Dy is indispensablein high performance permanent magnet
g(Nd10Dy4)Fe80B6
LED ill i ti l
g p p gQuantitative Risk(Rare)+eccentrically-distributed in
China, Country Risk↓Challenge for Dy-free magnet
Analysis and control of nano-structure
Doping Eu2+ into Si-Al-O-N structure↓
Heat resistant and long life
LED illumination lampNd and Cu mapping by 3DAP
Daylight colorDaylight white
Light bulbWhite colorWarm white
Fluorescent in RED, GREEN colors + Blue LED⇒ LED light source with excellent color reproducibility
Mass-produced for backlightOf Liquid crystal TV and cell-
phone 13=20kOe Coercive force=16kOe
Diffusing Nd-Cu Alloy in grain boundary
A new center on Elements Science and Technology A new center on Elements Science and Technology at NIMS from FY2011at NIMS from FY2011
Steel, Mg-alloy, Ti-alloy, Stainless-steel,
Micro-, Nano-, Atomic-scale characterization of materials -
Steel, Mg alloy, Ti alloy, Stainless steel,
Hierarchical control of metallic texturecharacterization of materials -understand roles of alloying elements
Hierarchical control of metallic textureInnovative process techniques to
improve properties
From the Urban Mines
Introducing active atoms into inter-
From the Urban Mines
metallic alloyMorphology control in nano-scale
Mesoporous materials precisely modified pore accuracy
SummarySummary
2005 A feasibility study on the development of Dy-free NdFeB magnets wasapproved by NEDO to a team lead by Sagawa.y y g
TOYOTA started a consortium for Dy free NdFeB magnets in Japan. Later, itwas expanded to four teams from EU.
2007 METI called proposal on Rare Metal Substitute Materials DevelopmentProject, which cover Dy, In, and W.
MEXT called proposals on basic research on Elements Science andMEXT called proposals on basic research on Elements Science andTechnology
2008 TOYOTA funded NIMS-TOYOTA Research Center for Dy-free permanentmagnets and all solid Li-ion battery research.
2010 JST called proposals on Elements Science and Technology as its largegrant scheme CREST and PREST for FY2011grant scheme, CREST and PREST for FY2011.
2011 NIMS will start "Elements Science and Technology Center".
Elements Science and Technology is being recognized as important researchElements Science and Technology is being recognized as important researchdiscipline in Japan getting supports form both MEXT and METI.