Tailored Metal Injection Moulding Of Isotropic NdFeB … · 25-10-2017 · Tailored Metal Injection...
Transcript of Tailored Metal Injection Moulding Of Isotropic NdFeB … · 25-10-2017 · Tailored Metal Injection...
09.11.2017
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Tailored Metal Injection MouldingOf Isotropic NdFeB Hard Magnets
Based On Recycled Powders
Prof. Dr. Carlo Burkhardt
Workshop in the frame of the WorldResources Forum – 25 October 2017Info Session
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
1) Prof. Dr. Ralf Wehrspohn, Kritikalität Seltener Erden, Fraunhofer Industrieworkshop „Magnetwerkstoffe“ ,Bremen, 19.05.20152) F. Meyer, Recycling von Nd aus Nd-Fe-B Magneten in Elektroaltgeräten, HS Hamburg, 16.04.20123) M. Buchert, Untersuchungen zu seltenen Erden: Permanentmagnete im industriellen Einsatz in Baden-Württemberg, Stuttgart,13.11.2013
For recycling potentially available Nd-Fe-B-magnets(Germany alone):
• Computer/Laptops > 60t/a (~10g/item)1)
• Passenger cars (ICE) > 450 t/a (~1 kg/car)2)
• Industrial electric motors > 30 t/a (0,05–2 kg/item)3)
> 500 t/a
Outlook:Recycling quantities currently negligible, but relevant forthe future (~5-20 years):
• Hybrid cars > 10 kg/car• Electric cars > 30 kg/car• Wind turbines > 600 kg/MW
100% waste-free production of complexely shaped Rare-Earth mag-nets (Nd-Fe-B) using recycled magnets in a closed material loop
Workshop in the frame of the WorldResources Forum – 25 October 2017ReProMag
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
09.11.2017
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What is REProMag?
Processing Parameters
Results
Summary and Outlook
Workshop in the frame of the WorldResources Forum – 25 October 2017Introduction
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
Duration: 1.1.2015 – 31.12.2017Funded Budget: 5,7 Mio €uro
14 Partners from 5 European Countries
OBE Ohnmacht & BaumgärtnerGmbH & Co. KG, Ispringen (D)
University of Birmingham (GB)Technische Universität Wien (A)Montanuniversität Leoben (A)Institut Jozef Stefan Ljubljana (SLO)National Physics Laboratory Sheffield (GB)
FOTEC GmbH, Wiener Neustadt (A)Pt+A GmbH, Dresden (D)Hage GmbH, Obdach (A)Lithoz, Wien (A)TEKS s.a.r.l., Montgenèvre (F)
Siemens A.G., München (D)Sennheiser GmbH & Co. KG, Wedemark (D)
Steinbeis Europa-Zentrum, Karlsruhe (D)
Workshop in the frame of the WorldResources Forum – 25 October 2017Introduction
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
09.11.2017
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HD (hydrogen decrepitation) process
Workshop in the frame of the WorldResources Forum – 25 October 2017The SDS process
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
HD (hydrogen decrepitation) process
(1) MIM(metal injection
moulding)
(2) FFF(fused filamentfabrication)
(3) LAM(lithography-basedadditivemanufacturing)
Workshop in the frame of the WorldResources Forum – 25 October 2017
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
The SDS process
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HD (hydrogen decrepitation) process
(1) MIM(metal injection
moulding)
(2) FFF(fused filamentfabrication)
(3) LAM(lithography-basedadditivemanufacturing)
Workshop in the frame of the WorldResources Forum – 25 October 2017
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
The SDS process
HD (hydrogen decrepitation) process
(1) MIM(metal injection
moulding)
(2) FFF(fused filamentfabrication)
(3) LAM(lithography-basedadditivemanufacturing)h
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Workshop in the frame of the WorldResources Forum – 25 October 2017
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
The SDS process
09.11.2017
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HD (hydrogen decrepitation) process
(1) MIM(metal injection
moulding)
(2) FFF(fused filamentfabrication)
(3) LAM(lithography-basedadditivemanufacturing)
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Workshop in the frame of the WorldResources Forum – 25 October 2017
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
The SDS process
What is REProMag?
Processing Parameters
Results
Summary and Outlook
Workshop in the frame of the WorldResources Forum – 25 October 2017SDS-Processing
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
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Powder Binder Handling Alignment Heat Treatment
+ NdH2Nd Dy Pr Fe Co B Cu Nb Al
wt% 27.3 4.42 0.35 61.1 4.44 1.05 0.04 0.87 0.36
Workshop in the frame of the WorldResources Forum – 25 October 2017
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
SDS processing
POLAR UNPOLAR
Powder Binder Handling Alignment Heat Treatment
Hydrogen atom
Carbon atom
Oxygen atomO. Weber, Dissertation, Universität Freiburg, 2015
Workshop in the frame of the WorldResources Forum – 25 October 2017
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
SDS processing
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expensive
Powder treatment
Compounding
Shaping
Ar
air Ar Ar
air air Ar
cheap
Powder Binder Handling Alignment Heat Treatments
Workshop in the frame of the WorldResources Forum – 25 October 2017
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
SDS processing
(0,6-0,8) T
Powder Binder Handling Alignment Heat Treatments
Workshop in the frame of the WorldResources Forum – 25 October 2017
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
SDS processing
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time
tem
pe
ratu
re
thermaldebinding
sintering
Powder Binder Handling Alignment Heat Treatments
− Sinteringtemperature
− Sintering time− Atmosphere− Sintering trays
− Kinetics− Atmosphere
C. Burkhardt, Metallpulverspritzguss –Fertigung komplexer Bauteile in höchsterPräzision, 2013
Workshop in the frame of the WorldResources Forum – 25 October 2017
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
SDS processing
< 1,0 wt.% < 0,1 wt.%
source: “MIM magnets in the REEgainproject”, DTU
Powder Binder Handling Alignment Heat Treatments
Workshop in the frame of the WorldResources Forum – 25 October 2017
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
SDS processing
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binder decomposition powder dehydration
Powder Binder Handling Alignment Heat Treatments
Workshop in the frame of the WorldResources Forum – 25 October 2017
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
SDS processing
What is REProMag?
Processing Parameters
Results
Summary and Outlook
Workshop in the frame of the WorldResources Forum – 25 October 2017Results
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
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Oxygen content (wt.%)
Hci
(kA
/m)
Carbon content (wt.%)
Hci
(kA
/m)
Hci intrinsic coercivity (kA/m) as a function of oxygen and carbon content
Workshop in the frame of the WorldResources Forum – 25 October 2017Results
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
ρ = 7,3 g/cm³
ρ = 6,9 g/cm³
ρ = 6,3 g/cm³
ρ = 7,4 g/cm³
Br: 644 mTHcj: 1061kA/m
polar binder
unpolar binder
protectiveatmosphere
alignment
heat treatment
Br: 603 mTHcj: 1296kA/m
Workshop in the frame of the WorldResources Forum – 25 October 2017Results
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
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Material characterisation of isotropic SDS magnets (no alignment in tooling)
Nd Dy Pr Fe Co B Cu Nb Al
wt% 27.3 4.42 0.35 61.1 4.44 1.05 0.04 0.87 0.36
Scrap magnets before HD process MIM magnets after SDS process
Nd2Fe14B-matrix
Nd-rich
Workshop in the frame of the WorldResources Forum – 25 October 2017
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
Results
Material characterisation of isotropic SDS magnets (no alignment in tooling)
„under“sintered microstructure
Nd2Fe14B-matrix
Nd-rich
Workshop in the frame of the WorldResources Forum – 25 October 2017Results
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
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„over“sintered microstructure
Nd2Fe14B-matrix
Nd-rich
Free Fe
Workshop in the frame of the WorldResources Forum – 25 October 2017Results
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
Material characterisation of isotropic SDS magnets (no alignment in tooling)
optimised microstructure, Nd-additions help to increase density
Nd2Fe14B-matrix
Darker Nd-richBrighter Nd-rich
Workshop in the frame of the WorldResources Forum – 25 October 2017Results
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
Material characterisation of isotropic SDS magnets (no alignment in tooling)
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What is REProMag?
Processing Parameters
Results
Summary and Outlook
Workshop in the frame of the WorldResources Forum – 25 October 2017Outlook
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
Processing parameters optimised for„coarse“ recycling powders (HDD)
Results for jet-milled powders in progress
Results for powders with Nd-additions inprogress
Feedstock developmentsuccessful completed
Feedstock develop-ment in progress
Alignment in tooling inprogress
starting magnets (sintered)Hci ~ 1350 kA/m
recycled SDS magnetsHci ~ 1300 kA/m
Hci ~96% of starting values
Fine-Tuning of processing para-meters for other powder sources
Upscaling for serialproduction
Follow-up projectssubmitted
Workshop in the frame of the WorldResources Forum – 25 October 2017
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
http://repromag-project.eu/
Outlook
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Thank you
Project funded by the European Union’s Horizon 2020 researchand innovation programme under the Grant Agreement n°636881
http://repromag-project.eu/
Workshop in the frame of the WorldResources Forum – 25 October 2017Contact
Project funded by the European Union’s Horizon 2020 researchand innovation programme under Grant Agreement No. 636881
OBE Ohnmacht & BaumgärtnerGmbh & Co. KGTurnstrasse 22
75228 Ispringen/Germany+49 7231 802 215
www.repromag-project.eu
http://repromag-project.eu/
Prof. Dr. Carlo Burkhardt