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PROCESSAMENTO


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Do Processamento Performance

Microstructura Propriedades

Processamento

Performance

Nd-Fe-B

PERFORMANCEPERFORMANCEtcnica e econmica


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Obteno da Liga

Obteno da Liga

Fuso Queima Reduo Difuso Sintese mecnica Sputtering


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Produo da Liga

Fuso

Gs inerte

Bomba de vcuo

Cadinho de Alumina

Bobinas de induo (1400 oC)

Contaminao com Alumnio


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Produo da Liga

a

d

c

b

Microestrutura da Ligade Nd16Fe76B8 Fundida


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Produo da Liga

Microestrutura da Ligade Nd16Fe76B8 Fundida


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Produo da Liga

Evaporao de Samrio


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Produo da Liga

Sm2Fe17 FundidoLingote(Virgem/homogeneizado)

Lingote Homogeneizado

Fe=9% e Sm2Fe17=91%

Lingote No Homogeneizado

Fe=10%, Sm2Fe17=82% e SmFe2/3=8%


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Produo da Liga

Diagrama de Equilibrio

Sm-Fe


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Produo da Liga

Fuso

Ligas base de Nd - principal processo produtivo

Ligas base de Sm - processos alternativos que operam emtemperaturas mais baixas


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Produo da Liga

Reduo Calciotrmica

8Nd2O3 + 64Fe +20Fe0.6B0.4 + 24Ca

8Nd2O3 + 4B2O3 + 5Fe2O3 + 64Fe + 51Ca

Nd16Fe76B76 + 24CaO

Nd16Fe76B76 + 51CaO


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Produo da Liga

Reduo Calciotrmica

Sm2O3 + 17Fe + 3Ca Sm2Fe17 + 3CaO


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Etapas intermedirias

ETAPAS INTERMEDIRIAS

Objetivos:

a) preparar o material para a etapa de consolidao/conformao e shaping

b) adequar a microestrutura


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Obteno de PartculasMonocristalinas

Moagem Mecnica

Moagem Qumica (HD)

Obs. Os processos de resfriamento rpido, atomizao e sntese mecnicapermitem a obteno de material particulado, mas em nenhum dos dois

casos as partculas so monocristalinas

O processo de Reduo Calciotrmica permite a obteno de umgrande numero de partculas monocristalinas diretamente aps aobteno da liga.


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Obtencao de ParticulasMonocritalinas


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MOAGEM QUMICADIFUSO DE HIDROGNIO POR CONTORNO DE GRO


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Grau de Alinhamento verificado viaVSM

-1,5 -1,0 -0,5 0,0 0,5 1,0 1,5

-1,5

-1,2

-0,9

-0,6

-0,3

0,0

0,3

0,6

0,9

1,2

1,5

J

(T)

He(T)

Jf= 1,24

Jd= 0,64

Br= 0,84

jHc= 0,076

BHmx

= 17,9

Sm2Fe17Nx produzido com pHoeganaes Ancor MH100

volta


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Resfriamento Rpido


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Espetro de um Slido Cristalino

Resfriamento Rpido


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Resfriamento Rpido


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Atomizao


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HDDR


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HDDR


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RECOMBINAO


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RECOMBINAO


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RECOMBINAO


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RECOMBINAO


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Modificacao Microestrutral

HDDR

Resfriamento Rapido

Sinterizacao


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Processos de Consolidacao

SINTERIZADOS

Compactacao Uniaxial + Sinterizcao

Compactacao Isostatica + Sinterizacao

Compositos

ROTAS ALTERNATIVAS

Injecao + Sinterizacao

Extruso

Objetivos:

a) Dar forma ao material

b) Adequar a microestrutura


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Por que Sinterizar ?

Permite a densificar os components (ps)

Permite melhor controle microestrutural.

Permite a precipitao de fases, xidos (nos contornosde gro) e controle no tamanho de gro.

Processo mais produtivo que a fuso.

Proporciona um melhor controle da estequiometria.


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SINTERIZAO DA LIGA


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Dificuldades atuais na fabricao de


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ms base de SmSm22FeFe1717NN33

A introduo de nitrognio s vivel a partir de reao do tipo gs slido, mas o processo de difuso lento.

Assim, a fase SmSm

22FeFe

1717NN

33, atualmente, s pode ser produzida na forma de p.

A Fase SmSm

22FeFe

1717NN

33 metaestvel e se decompe em SmN e Fe em temperaturas superiores a 550 oC.

Esta decomposio inviabiliza o processo de sinterizao como meio para densificar os ms.


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Sinterizao


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Sinterizao


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Sinterizao - Resultados

Mi t t


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Microestrutura

Mi t t


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Microestrutura


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Processos de ConsolidacaoMetal Bonding



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Processos de ConsolidacaoMetal Bonding

Rotas Alternati as


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Textura

Alinhamento de gros

Rotas AlternativasExtruso


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Mtodos de


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Mtodos deRecobrimento/Proteo


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Recomendaes Finais


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Seleo de Materiais

Si t i d


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Sinterizados

Compositos Injetados


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Compositos Injetados


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Compositos Compactados


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Material - NdFeB


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Material SmCo5


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Material - Ferrites


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Critrios de Seleo

Aichi Steel Develops Process That


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Aichi Steel Develops Process ThatHalves Plastic Magnet Costs

Nagoya, March 6, 2000 - Today Aichi Steel developed the world's first cobalt-free production process for neodymium based non-isotropic magneticpowder here and has launched a new plastic magnet (called Magfine 18/20)that uses this magnetic powder. The process reduces the price of the plastic

magnet by up to 50 percent compared with the conventional plastic magnetproduced with the traditional process of using cobalt.

Not only does the new process (called the d-HDDR method) reduce costs. Theproduct's magnetic intensity is nearly one third stronger and has a upperworking temperature limit 140oC higherthan the conventional type. Moreover,the new magnet reduces energy use in motors of electric appliances by 30percent and miniaturizes the motor for information processing equipment by 30percent. The company expects the product to be applied in motors for electriccars in the near future.

Aichi Steel has been test-marketing the new product in limited numbers since1999 and is now ready to launch the plastic magnet on a commercial basis. Thenew production plant of magnetic powder and plastic magnets has a capacity offive tons per month.

MAGNEQUENCH, DAIDO STEEL DEVELOP


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,WORLD'S HIGHEST ENERGY PRODUCT

Press Release Anderson, Ind. - March 21, 2002 - Magnequench Inc. and Daido Steel Co.,

Ltd. developed new high energy, anisotropic Neodymium-Iron-Boron (Nd-Fe-B) magnets. The bonded magnets have the world's highest energyproduct with 22 MGOe (160 KJ/m3) as well as high heat resistance with thecapability of operating at temperatures of more than 100C. In addition, theprice of the newly developed anisotropic bonded magnets offer more flux

per dollar when compared with isotropic bonded magnets. The two new types of Nd-Fe-B bonded magnets are superior to magneticmaterials produced by alternative HDDR process. The high-energy producttype (BH) max is greater than HDDR magnets by 10 percent whilemaximum operating temperature is 100C which is higher than that ofHDDR magnets by 20C. High temperature usage type energy product (BH)max is 17 MGOe with a maximum operating temperature of 120C which is

higher than that of similar strength HDDR magnets which can only operateup to 100C.

Development of Nd Fe B Anisotropic Bonded


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Development of NdFeB Anisotropic BondedMagnet With 27 MGOe

AbstractThe maximum energy product of bonded magnets is advancing every year. The highest maximum energy product of any bonded magnet achieved is 25 MGOe (200 kJ/m3) in the NdFeB system by d-HDDR treatment. There is a great demand for even higher energy bonded magnets with the desire for smaller, more efficient electric motors. Bonded magnets made from

d-HDDR treated anisotropic magnet powder have low squareness due to low squareness of the powder. The authors developed a method to increase squareness of d-HDDR powder, and succeeded in developing the worlds highest energy bonded magnet with 26.6 MGOe (213 kJ/m3). This was achieved through Dy-diffusion treatment followed by d-HDDR treatment, as well as an increase in the density of the bonded magnet. This magnet has little aging loss after being held at 393 K for 878 h.

IEEE TRANSACTIONS ON MAGNETICS, VOL. 39, NO. 5, SEPTEMBER 2003 2953

N. Hamada, C. Mishima, H. Mitarai, and Y. Honkura


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THE COMPARISON OF ANISOTROPIC (AND ISOTROPIC)POWDERS FOR POLYMER BONDED RARE EARTH PERMANENT

MAGNETS

One example of this poor magnetic performance experienced byHDDR type magnets at elevated temperatures was presented in arecent publication, which showed a standard d-HDDR magnet tolose 5% flux at 80oC (353K) and a Dy containing d-HDDR magnet

to lose 5% flux at 137oC (415K).5 Considering both of these testswere carried out in an inert argon atmosphere and over only threeminutes, both magnets demonstrated poor thermal stability.

D. N. BROWN, B-M MA and P. CAMPBELLMagnequench Technology Center, 9000 Development Drive

Research Triangle Park, P.O. Box 14827, NC 27709

Development of NdFeB Anisotropic Bonded


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p pMagnet With 27 MGOe


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