Search Results (54)

The growing demand for rare-earth magnets has raised concerns over their price and the country’s risk of depleting the supply of rare-earth elements. These severe concerns have led to the study of rare-earth-free magnets that do not rely on rare-earth elements. Co-Zr-Mo-B alloys, one of the prospective candidates for rare-earth-free magnets, were produced by the melt-spinning technique and subsequent annealing. It was found that a small substitution of Mo for Zr in the Co-Zr-B alloys increased coercivity. The Co-Zr-Mo-B alloy with a Mo content of 2 at% showed a high coercivity of 6.2 kOe with a remanence of 40 emu/g. SEM studies showed that the annealed Co-Zr-Mo-B alloys had fine, uniform grains with an average diameter of about 0.6 μm. Further studies using STEM demonstrated that the ferromagnetic phase in the annealed Co-Zr-Mo-B alloys with high coercivity was composed of the Co₅Zr phase and the long-period stacking ordered (LPSO) phase. That is, the fine grains observed in the SEM studies were found to be ferromagnetic dendrites containing numerous twin boundaries of the Co₅Zr phase and its derived LPSO phase. Therefore, the high coercivity of the Co-Zr-Mo-B alloys can be attributed to the presence of ferromagnetic crystals of Co₅Zr and the derived LPSO phase. Full article

The instability in rare-earth material supply and rising costs have driven research into rare-earth-free electric motors. Among various alternatives, wound rotor synchronous motors (WRSMs) stand out due to their adjustable excitation, enabling high torque at low speeds, and efficient field weakening at high speeds. Unlike permanent magnet synchronous motors (PMSMs), WRSMs offer greater operational flexibility and eliminate the risk of demagnetization. However, accurately modeling WRSMs remains challenging, especially when considering axial fringing flux and leakage components, which significantly affect motor performance. To address this challenge, this paper proposes a 3D nonlinear magnetic equivalent circuit (MEC) model that explicitly incorporates axial flux components and leakage paths in WRSMs with overhang rotor structures. Unlike conventional 2D MEC models, which fail to capture axial flux interactions, the proposed approach improves prediction accuracy while significantly reducing computational costs compared to full 3D finite element analysis (FEA). The model was validated through comparisons with 3D FEA simulations and experimental back-EMF measurements, demonstrating its accuracy and computational efficiency. The results confirm that the 3D nonlinear MEC model effectively captures axial flux paths and leakage components, making it a valuable tool for WRSM design and analysis. Future research will focus on further refining the model, incorporating hysteresis loss modeling, and developing hybrid MEC–FEA simulation techniques to enhance its applicability. Full article

Fe₂P (iron phosphide) alloys have garnered significant interest in recent years due to their potential applications in permanent magnet materials, particularly in the context of energy-efficient and environmentally friendly technologies. We have sought to tailor the magnetic properties, such as magnetization, coercivity, and Curie temperature, to meet the specific requirements of rare-earth-free permanent magnets for various industrial sectors. In this work, we review recent advancements in the exploration of substitutions (Si, Co, Mn, and Ni) within $\mathrm{F}{\mathrm{e}}_2\mathrm{P}$ alloys aimed at enhancing their magnetic performance as candidates for permanent magnets. The X-ray patterns of (Fe,Co)₂P show great crystallinity with a pure Fe₂P phase even with Mn and Ni substitutions. The Fe₂P structure crystallizes in the P-62m space group. It has been confirmed that the transition metals substitute the 3g Fe-site, sometimes with adverse effects regarding magnetic properties with Co vs. Ni substitution, and that Si substitutes the 2c P-site. The saturation magnetization increases ($M_S=87\mathrm{A}{\mathrm{m}}^2/\mathrm{k}\mathrm{g}$) with Mn substitution, while the Curie temperature decreases with these substitutions. The impact of various substitutional elements on the magnetic properties of $\mathrm{F}{\mathrm{e}}_2\mathrm{P}$ alloys is highlighted, and challenges encountered in this field are reported. Full article

This work presents a comparative study of five rare earth compounds—Erbium nitrate pentahydrate lll (Er), Neodymium nitrate pentahydrate (Nd), Samarium III Nitrate Hexahydrate (Sm), Yterbium III Chloride Hexahydrate (Yb) and Praseodymium nitrate hexahydrate lll (Pr)—protecting API 5L X70 steel from corrosion in saline medium that uses electrochemical impedance spectroscopy (EIS) and polarization curves (CPs) at different concentrations and in static mode. The results show that Erbium is the best corrosion inhibitor, containing 50 ppm and reaching an inhibition efficiency of about 89%, and similar result was shown by Sm with an IE~87.9%, while the other rare earths (Nd, Yb and Pr) showed a decrease in corrosion protection at the same concentration, since they were below an IE~80%. On the other hand, with the Langmuir model it was possible to describe that the adsorption process of the three rare earths follows a combined physisorption–chemisorption process to protect the metal’s surface. The observed adsorption free energy, ΔG°ads, reaches −38.7 kJ/mol for Er, −34.4 kJ/mol for Nd, and −33.6 kJ/mol for Pr; whereas Sm and Yb have adsorption free energies of −33.9 and −35.0 kJ/mol, respectively. Scanning electron microscopy (SEM) and atomic force microscopy (AFM) further confirmed the formation of a protective film. Their characterization using density functional theory showed the transference of charge from the iron cluster towards the rare earth metal compounds. The adsorption process produced a slightly polarized region of interaction with the metal surface. Also, it was found that the adsorption of the rare earths affected the magnetic properties of the surface of the iron cluster. Quantum chemical descriptors, such as Pearson’s HSAB (Hard and Soft Acids and Bases) descriptors, were useful in predicting the behavior of the flow of electrons between the metal surface and the interacting rare earth ions. Full article

Metal amorphous nanocomposite (MANC) soft magnetic materials exhibit remarkably low iron loss and high saturation magnetization. However, they have not been widely used in electric motors largely due to a lack of demonstrated manufacturing processing methods and an absence of proven motor designs well suited for their use. Recent developments in these two areas have prompted the optimization study of flux-switching with permanent magnet motor topology using MANCs presented here. This study uses population-based optimization in conjunction with a simplified electromagnetics model to seek rare earth-free designs that attain or exceed the state of the art in power density and efficiency. To predict the maximum mechanically safe rotational speed for each design with minimal computational effort, a new method of quantifying the rotor assembly mechanical limit is presented. The resulting population of designs includes motor designs with a specific power of up to 6.1 kW/kg and efficiency of up to 99% without the use of rare earth permanent magnets. These designs, while exhibiting drawbacks of high electrical frequency and significant manufacturing complexity, exceed the typical power density of representative state-of-the-art EV motors while increasing efficiency and eliminating rare earth elements. Full article

The transportation sector is experiencing a profound shift, driven by the urgent need to reduce greenhouse gas (GHG) emissions from internal combustion engine vehicles (ICEVs). As electric vehicle (EV) adoption accelerates, the sustainability of the materials used in their production, particularly in electric motors, is becoming a critical focus. This paper examines the sustainability of both traditional and emerging materials used in EV traction motors, with an emphasis on permanent magnet synchronous motors (PMSMs), which remain the dominant technology in the industry. Key challenges include the environmental and supply-chain concerns associated with rare earth elements (REEs) used in permanent magnets, as well as the sustainability of copper windings. Automakers are exploring alternatives such as REE-free permanent magnets, soft magnetic composites (SMCs) for reduced losses in the core, and carbon nanotube (CNT) windings for superior electrical, thermal, and mechanical properties. The topic of materials for EV traction motors is discussed in the literature; however, the focus on environmental, social, and economic sustainability is often lacking. This paper fills the gap by connecting the technological aspects with sustainability considerations, offering insights into the future configuration of EV motors. Full article

Rare-earth-based permanent magnets (PMs) have a vital role in numerous sustainable energy systems, such as electrical machines (EMs). However, their production can greatly harm the environment and their supply chain monopoly presents economic threats. Alternative materials are emerging, but the use of rare-earth PMs remains dominant due to their exceptional performance. Damage to magnet structure can cause loss of performance and efficiency, and propagation of cracks in PMs can result in breaking. In this context, prolonging the service life of PMs and ensuring that they remain damage-free and suitable for re-use is important both for sustainability reasons and cost management. This paper presents a new harmonic content diagnosis and motor performance analysis caused by various magnet structure defects or faults, such as cracked or broken magnets. The proposed method is used for modeling the successive physical failure of the magnet structure in the form of crack formation, crack growth, and magnet breakage. A surface-mounted permanent magnet synchronous motor (PMSM) is studied using simulation in Ansys Maxwell software (Version 2023), and different cracks and PM faults are modeled using the two-dimensional finite element method (FEM). The frequency domain simulation results demonstrate the influence of magnet cracks and their propagation on EM performance measures, such as stator current, distribution of magnetic flux density, back EMF, flux linkage, losses, and efficiency. The results show strong potential for application in health monitoring systems, which could be used to reduce the occurrence of in-service failures, thus reducing the usage of rare-earth magnet materials as well as cost. Full article

Tetrataenite is a promising candidate for rare earth-free permanent magnets due to its low cost and intrinsic magnetic properties. This work investigates the effect of combined milling at liquid nitrogen temperatures (cryomilling) and the addition of carbon as an interstitial element for promoting the formation of tetrataenite. Crystal structure, microstructure, and magnetic properties are investigated to understand the influence of mechanical processing and compositional modifications. No unambiguous evidence of the ordered phase of tetrataenite is found in the structural characterization. However, using Scanning Transmission Electron Microscopy (STEM) and powder X-ray diffraction (PXD) analyses, the occurrence of both twinning and stacking faults resulting from the high-energy milling process is observed, which is a relevant factor for identifying tetrataenite in FeNi alloys. The probability of a stacking fault and twinning occurring for a carbon-free FeNi sample before annealing is found to be 2% and 1.4%, respectively. After annealing, the stacking fault probability decreased to 1.2%, while that of twinning was 1.4%. By increasing the carbon concentration to 5 at.%, the stacking faults and twinning probabilities decrease slightly to 1.2% and 1.3%, respectively. The occurrence of stacking faults combined with small crystallite sizes was a hindering factor in identifying the presence of tetrataenite. Full article

To realize rare-earth-free magnets, we studied iron nitride (α″-Fe₁₆N₂) magnets, which contain no rare-earth elements. Fe-N powder with the α″-Fe₁₆N₂ phase has a high saturation magnetization comparable to high-performance rare-earth magnets but is not stable at temperatures over 539 K. We consolidated Fe-N powder into bulk material at low temperatures by spark plasma sintering (SPS) and spark plasma sintering with dynamic compression (SPS-DC). Fe-N magnets were successfully obtained at low temperatures of 373–573 K. The magnets produced by the SPS-DC method had a higher density than those produced by the SPS method. The density of the magnets produced by the SPS-DC method increased as the consolidation temperature increased. That produced at 373 K had a saturation magnetization of 1.07 T with a coercivity of 0.20 MA/m. Full article

Rare earth bisphthalocyanines (MPc₂) are of particular interest because of their behavior as single-molecular magnets, which makes them suitable for applications in molecular spintronics, high-density data storage and quantum computation. Nevertheless, MPc₂ are not commercially available, and the synthesis routes are mainly focused on obtaining substituted phthalocyanines. Two preparation routes depend on the precursor: synthesis from phthalonitrile (PN) and the metalation of free or dilithium phthalocyanine (H₂Pc and Li₂Pc). In both options, byproducts such as free-base phthalocyanine and in the first route additional PN oligomers are generated, which influence the MPc₂ yield. There are three preparation methods for these routes: heating, microwave radiation and reflux. In this research, solvothermal synthesis was applied as a new approach to prepare yttrium, lanthanum, gadolinium and terbium unsubstituted bisphthalocyanines using Li₂Pc and the rare earth(III) acetylacetonates. Purification by sublimation gave high product yields compared to those reported, namely 68% for YPc₂, 43% for LaPc₂, 63% for GdPc₂ and 62% for TbPc₂, without any detectable presence of H₂Pc. Characterization by infrared, Raman, ultraviolet–visible and X-ray photoelectron spectroscopy as well as elemental analysis revealed the main featuresof the four bisphthalocyanines, indicating the success of the synthesis of the complexes. Full article

In the last decade, permanent magnet (PM)-free or hybrid PM machines have been extensively researched to find an alternative for high cost rare-earth PM machines. Brushless wound rotor synchronous machines (BL-WRSMs) are one of the alternatives to these PM machines. BL-WRSMs have a lower torque density compared to PM machines. In this paper, a new topology is introduced to improve the torque producing capability of the existing BL-WRSM by utilizing the vacant spaces in the rotor slots. The new topology has two harmonic windings placed on the rotor which induce separate currents. A capacitor is used between the two harmonic windings to bring the currents in phase with each other. The harmonic winding currents are fed to the rectifier which is also placed on the rotor. Due to additional harmonic winding, the overall field current fed to the rotor field winding has been increased and hence the average torque has also increased. Finite element analysis (FEA)-based simulations are performed using ANSYS Maxwell to validate the proposed topology. The results show that the average torque of the machine has been significantly increased compared to the reference model. The detailed comparison results are provided in this paper. Full article

Recently, due to the price fluctuation and supply instability of rare earth mineral resources, there has been a lot of development of electric motors using non-rare-earth permanent magnets. As a result, motors using Dy-free permanent magnets and ferrite permanent magnets are being researched, and, in particular, ferrite permanent magnets often utilize spoke-type structures, which are magnetic flux concentrators, to compensate for their low coercivity and residual flux density. However, in general, spoke-type PMSMs do not use much reluctance torque, so double-layer spoke-type PMSMs have been studied for their more efficient design. Unlike general spoke-type PMSMs, double-layer spoke-type PMSMs can utilize high reluctance torque by increasing the difference between d-axis and q-axis reluctance. However, as the difference in magnetic resistance increases, vibration and noise are generated, which adversely affects the mechanical part and shortens the life of the motor. Although this problem seemed to be solved by applying core skew in the previous study, it was confirmed that the axial force caused by the axial leakage flux occurred in the maximum torque per ampere (MTPA) control section and the torque ripple was increased. Therefore, in this paper, a model that can apply symmetrical core skew and reduce axial force is proposed. First, the causes of the axial force generated in previous studies were analyzed. Based on the analysis of these causes, a new symmetrical core skew structure was proposed, and its justification was verified through FEA. Full article

Permanent Magnet-Assisted Synchronous Reluctance Machines (PMASynRM) provide a low-cost alternative to Surface PM Machines due to the use of relatively lower grades of rare-earth (RE) or RE-free magnets, as the performance degradation due to weaker magnets is compensated by the presence of reluctance torque. However, the weaker magnets suffer from a high risk of demagnetization, leading to unreliable motor operation. Using a blend of RE and RE-free magnets has the potential to overcome this issue. This paper proposes to blend different grades of various rare-earth (RE) and rare-earth-free (RE-free) magnets in six different combinations and utilizes them in two-layer and three-layer U-shaped PMASynRM topologies with both eight-pole and six-pole variations. The rotor of the various designs is then optimized using a differential evolution (DE) based optimization algorithm to obtain low-cost designs with reduced RE magnet volume and minimum demagnetization risk. The optimization of each design is also integrated with the evaluation of mechanical stresses in the rotor laminations so as to maintain the stresses below the material yield strength. Furthermore, the various performance metrics, such as toque–speed/power–speed characteristics, demagnetization, and efficiency maps, are evaluated for each of the optimized and mechanically feasible designs. A quantitative comparison of the various optimized designs is also obtained to highlight the various trade-offs. The results indicate the feasibility of meeting the baseline torque requirement across the entire speed range, even with a 100% reduction in RE magnet volume and less than 5% demagnetization risk, while achieving a cost reduction exceeding 50%. Moreover, the two-layer, eight-pole designs exhibit relatively higher performance, whereas the three-layer, eight-pole designs are found to be the most economical option. Full article

Mn-based magnets are known to be a candidate for use as rare-earth-free magnets. In this study, Mn-Ga bulk magnets were successfully produced by hot pressing using the spark plasma sintering method on Mn-Ga powder prepared from rapidly solidified Mn-Ga melt-spun ribbons. When consolidated at 773 K and 873 K, the Mn-Ga bulk magnets had fine grains and exhibited high coercivity values. The origin of the high coercivity of the Mn-Ga bulk magnets was the existence of the D0₂₂ phase. The Mn-Ga bulk magnet consolidated at 873 K exhibited the highest coercivity of 6.40 kOe. Full article

Band-structure calculations were performed using the spin-polarized relativistic Korringa–Kohn–Rostoker (SPR-KKR) band-structure method, determining intrinsic magnetic properties, such as magnetic moments, magnetocrystalline anisotropy energy (MAE), and Curie temperatures, of Fe_5−x−yCo_xM_ySiB₂ (M = Re, W) alloys. The general gradient approximation (GGA) for the exchange–correlation potential and the atomic sphere approximation (ASA) were used in the calculations. Previous studies have shown that for Fe₅SiB₂, the easy magnetization direction is in-plane, but it turns axial for Co-doping in the range 1 < x ≤ 2.5 (y = 0). Furthermore, studies have shown that 5d-doping enhances the MAE by enabling the strong spin–orbit coupling of Fe–3d and M–5d states. The aim of the present theoretical calculations was to find the dependence of the anisotropy constant K₁ for combined Co- and M-doping, building a two-dimensional (2D) map of K₁ for 0 ≤ x ≤ 2 and 0 ≤ y ≤ 1. Similar theoretical 2D maps for magnetization and Curie temperature vs. Co and M content (M = W and Re) were built, allowing for the selection of alloy compositions with enhanced values of uniaxial anisotropy, magnetization, and Curie temperature. The magnetic properties of the Fe_4.1W_0.9SiB₂ alloy that meet the selection criteria for axial anisotropy K₁ > 0.2 meV/f.u., Curie temperature T_c > 800 K determined by the mean-field approach, and magnetization µ₀M_s > 1 T are discussed. Full article