Maximum Energy Products (kJ/m )
3
60
400
50
320
40
240
30
160
20
80
10
0
0
Maximum Energy Products (MGOe)
480
Guiding principles which led to the new magnets:
Transition
Guiding principle
Old
New
Alnico
SmCo5
Getting high coercivity by using high anisotropy fields
originated from 4f electrons
SmCo5
Sm2Co17
Getting high remanence by using high saturation
magnetization of Sm2Co17
Sm2Co17
Nd2Fe14B
Getting an Fe-base magnet by extending the search for
R-Fe-X ternary systems with various R
(R=Rare Earth)
At MMM Conference, November 10, 1983
Map of the magnetic properties of the NdFeB sintered
magnets and corresponding applications
MRI, Speaker
50
HDD, CD, DVD, MD, VTR, Digital camera, Head phone
-50
BH)max MGOe
45
-48
-46BH
ABS sensor
-49H
40
OA FA motor
-40BH
35
X NEOMAX
N
NEOREC
30
10
-39SH
-38AH
Servo motor
Compressor motor
-35SH
-35EH
Motor for robotics
Generator
HEV driving motor
-32EH
20
HcJ kOe
30
Map of the magnetic properties of the NdFeB sintered
magnets and corresponding applications
MRI, Speaker
50
HDD, CD, DVD, MD, VTR, Digital camera, Head phone
-50
-48BH
-46BH
BH)max MGOe
45
-44H
40
OA FA motor
-42VH
-39SH
-38VH
35
30
2000
ABS sensor
Servo motor
Compressor motor
-35SH
-35EH
1987
Motor for robotics
Generator
HEV driving motor
-32EH
10
20
HcJ kOe
30
Process for the NdFeB sintered magnets
Raw
Materials
Nd, Dy, Fe, B
Melting
Course
Grinding
Jet
Milling
Compaction
Sintering
Annealing
Process for the NdFeB sintered magnets
Raw
Materials
Melting
Course
Grinding
Strip
Casting
Hydrogen
Decrepitation
Jet
Milling
Compaction
Nd, Dy, Fe, B
Improvements:
Lubricant
Low pressure
pressing
Binder
High magnetic
field
Low oxygen
process
Sintering
Annealing
Amount of Production(t/year)
NdFeB Sintered Magnets
Amount of Production(t/year)
NdFeB Bonded Magnets
Map of the magnetic properties of the NdFeB sintered
magnets and corresponding applications
MRI, Speaker
50
HDD, CD, DVD, MD, VTR, Digital camera, Head phone
-50
BH)max MGOe
45
-48BH
-46BH
ABS sensor
-44H
40
OA FA motor
-42VH
35
X NEOMAX
N
NEOREC
30
10
-39SH
-38VH
Servo motor
Compressor motor
-35SH
-35EH
Motor for robotics
Generator
HEV driving motor
-32EH
20
HcJ kOe
30
VCM
Application of NdFeB sintered magnets
(Pick-up for CD-ROM)
Tracking coil
Focus coil
NdFeB magnet
Optical pick-up
Lense
Application of NdFeB sintered magnet
(IPM compressor motor for air conditioner)
Outside the house
Compressor
Inside the house
NdFeB magnet
DC motor
IPM rotor
Air Conditioner
Induction motor
IPM synchronous motor
Efficiency isimproved by 20% statistically !
35km/liter!
Map of the magnetic properties of the NdFeB sintered
magnets and corresponding applications
MRI, Speaker
50
HDD, CD, DVD, MD, VTR, Digital camera, Head phone
-50
BH)max MGOe
45
-48BH
-46BH
ABS sensor
-44H
40
Strong needs
OA FA motor
-42VH
35
X NEOMAX
N
NEOREC
30
10
-39SH
-38VH
Servo motor
Compressor motor
-35SH
-35EH
Motor for robotics
Generator
HEV driving motor
-32EH
20
HcJ kOe
30
Composition of the NdFeB sintered magnets
31Nd-68Fe-1B
50
BH)max MGOe
45
26Nd-5Dy-68Fe-1B
40
Nature
Dy
35
Nd
21Nd-10Dy-68Fe-1B
0.1
30
10
20
HcJ kOe
30
Map of the magnetic properties of the NdFeB sintered
magnets and corresponding applications
MRI, Speaker
50
HDD, CD, DVD, MD, VTR, Digital camera, Head phone
-50
BH)max MGOe
45
-48BH
-46BH
Hybrid car application
requires this range !
ABS sensor
-44H
40
OA FA motor
-42VH
35
X NEOMAX
N
NEOREC
30
10
-39SH
-38VH
Servo motor
Compressor motor
-35SH
-35EH
Motor for robotics
Generator
HEV driving motor
-32EH
20
HcJ kOe
30
Direction of our development
50
BH)max MGOe
45
0% Dy
Incr
eas
ing
40
35
ani
sot
rop
y
30
10
20
HcJ kOe
30
Sintering
Pressless Process (PLP)
PLP
Coercivity of NdFeB sintered magnets (PLP Experimental data)
25
2.7μm 17kOe
20
HcJ kOe
2.9μm 16.5kOe
5μm 13.5kOe
15
10
1
1.5
2
3
3
4
5 6 7 8 9 10
4.5
6.0 7.5 9.0 12.0 15.0
D 1.5d
Particle size d μm
Grain size D μm
PLP Record
50
BH)max MGOe
45
0% Dy
(Particle
size=2.7μm
40
35
30
10
20
HcJ kOe
30
Prices of Rare Earths
/kg
Nd price also soars !
2005
2006
2007
/kg
Prices of Rare Earths
Our goal for PLP
Net Shape Production
Yield 90
New National Project in Japan
Subject:“Development of Alternative Materials
for Rare Metals”
Rare Metals:
W for toolings
Dy for NdFeB magnets
In for LCD
Term: 2007 2011
Budget: 5.5BJPY ( 34M€
Members for Dy: Intermetallics Co., Ltd.
Tohoku University
NationalInstitute for
Material Science etc.
Coercivity of NdFeB sintered magnets (PLP Experimental data)
25
2.7μm 17kOe
20
HcJ kOe
2.9μm 16.5kOe
5μm 13.5kOe
15
10
1
1.5
2
3
3
4
5 6 7 8 9 10
4.5
6.0 7.5 9.0 12.0 15.0
D 1.5d
Particle size d μm
Grain size D μm
Object of the National Project
50
BH)max MGOe
45
0% Dy
Present
level
40
35
30
10
20
HcJ kOe
30
How to reach the object ?
Athorough investigation about the relation
between microstructure and coercivityin NdFeB
magnets.
Athorough investigation about the mechanism of
the magnetization reversal,including calculations
based on the first principle.
Determination of the ideal structure for the NdFeB
magnet.
Determination of the process for the NdFeB
magnet with the ideal structure.
“NdFeB Magnets rescue the Earth.”
To rescue the Earth,let’s act:
All motors in allfactories →NdFeB PM motors
All motors for elevators → NdFeB PM motors
All motors for air conditioners →NdFeB PM motors
All motors for refrigerators → NdFeB PM motors
All motors for trains →NdFeB PM motors
Allcars →HEV or EV
Problems ?
Let’s overcome !
e. g.
Shortage of Nd, Dy ? → Find new mines !
Cost of NdFeB magnets ? → Find a way for cost
reduction !
Cost of HEV → Develop HEV with acceptable cost !
(Toyota is doing.)
Isitimpossible to find a new magnet
after the NdFeB magnet ?
To find a new magnet after the NdFeB magnet, a
new guiding principle must be found:
The guiding principle for the NdFeB magnet is
useless any more.
We have allsorts of mystery in the
coercivity of the NdFeB magnets.
Profound and thorough researches on
the coercivity of the NdFeB magnets
willgive us a new guiding principle for
a new magnet!