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Ferromagnetism

Ferromagnetism

Materials like iron, nickel, and cobalt consist of magnetic domains, within which the magnetic dipoles are arranged parallel to each other. The magnetic dipoles are rigidly aligned in the same direction within a domain by quantum mechanical coupling among the atoms. This coupling is so strong that even thermal agitation at room temperature cannot break it. The result is that each domain has a net dipole moment. However, some materials have weaker coupling, and are ferromagnetic at lower...

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Production of Anisotropic NdFeB Permanent Magnets with In Situ Magnetic Particle Alignment Using Powder Extrusion.

Stefan Rathfelder^1,2, Stephan Schuschnigg², Christian Kukla³

¹Institute for Precious and Technology Metals, Pforzheim University, Tiefenbronner Str. 65, 75175 Pforzheim, Germany.

Materials (Basel, Switzerland)

|August 14, 2025

Summary

This summary is machine-generated.

This study demonstrates sustainable production of neodymium-iron-boron (NdFeB) magnets using powder extrusion molding with in situ magnetic alignment. This method effectively recycles end-of-life magnets, achieving high particle alignment for advanced manufacturing.

Keywords:

anisotropic NdFeB permanent magnets metal injection molding (MIM)powder extrusion molding (PEM)recycling of end-of-life (Eol)-magnets

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Published on: January 3, 2018

Area of Science:

Materials Science
Manufacturing Engineering
Sustainable Technology

Background:

Neodymium-iron-boron (NdFeB) permanent magnets are critical for green technologies like wind turbines.
Recycling end-of-life (Eol) magnets is essential for resource sustainability.
Powder extrusion molding (PEM) offers a potential route for magnet manufacturing and recycling.

Purpose of the Study:

To investigate sustainable NdFeB magnet production using powder extrusion molding (PEM) with in situ magnetic alignment.
To optimize alignment tool geometry and magnetic field parameters for effective particle alignment during extrusion.
To demonstrate a scalable method for recycling Eol magnets into high-performance anisotropic magnets.

Main Methods:

Utilized recycled NdFeB powder from Eol wind turbine magnets processed via hydrogen processing of magnetic scrap (HPMS).
Employed Finite Element Method (FEM) simulations to design and optimize alignment tool geometries and magnetic field parameters.
Conducted extrusion experiments with varying alignment tool geometries and magnetic field strengths to determine optimal particle alignment configurations.

Main Results:

Achieved a high degree of particle alignment (Br/Js = 0.95) using PEM with in situ magnetic alignment.
Demonstrated alignment exceeding that of PEM without external magnetic fields (0.78).
Successfully produced anisotropic NdFeB permanent magnets without post-machining.

Conclusions:

Optimized alignment tool geometry and strong magnetic fields during extrusion enable the production of anisotropic NdFeB magnets.
PEM with in situ magnetic alignment provides a scalable route for permanent magnet recycling and manufacturing.
This continuous fabrication method allows for near-net-shape strands with customizable cross-sections.