MSE 2024
Poster
An alternative sintering strategy for anisotropic Nd-Fe-B magnets based on recycled content
TT

Tomaž Tomše (Ph.D.)

Hochschule Pforzheim

Tomše, T. (Speaker)¹; Burkhardt, C.²; Burkhardt, F.³; Kobe, S.³; Podmiljšak, B.³; Šturm, S.³; Žužek, K.³
¹Jožef Stefan Institute, Ljubljana (Slovenia); ²Hochschule Pforzheim; ³Jožef Stefan Institute (JSI), Ljubljana (Slovenia)

Nd-Fe-B permanent magnets contain approx. 30 wt.% of rare-earths (RE) and are valuable secondary sources of critical RE elements. Despite their significant technological and economic importance, less than 1% of the world's REEs are currently being recycled. In the EU alone, the estimated recycling potential in 2020 was 6,000 tons, roughly half of the Nd-Fe-B magnet demand for that year. The primary challenge in achieving resource-efficient magnet recycling lies in the unsustainability of existing recycling strategies. Conventional methods, such as chemical and pyrometallurgical processes, are costly, energy-intensive, and not aligned with circular economy principles. Recycling Nd-Fe-B magnets through conventional means is currently non-existent in the EU. To bolster recycling capacities, alternative and more environmentally friendly technologies for reclaiming critical REs must be explored. The highly efficient HPMS process (Hydrogen Processing of Magnet Scrap) offers a practical solution for disintegrating sintered end-of-life (EOL) Nd-Fe-B magnets into a friable, demagnetized powder. This powder can then be mechanically separated from other components of magnet-containing devices. However, the hard-magnetic properties of HPMS powders are poor and require further processing, including milling and re-sintering, to be utilized as building blocks for new magnets. Furthermore, the magnetic potential of the material depends on the extent of corrosion of EOL magnets and their chemical composition. To address these limitations, we propose an alternative rapid sintering strategy to enhance the performance of recycled magnets made from HPMS powders. By reducing the sintering time, we were able to improve the final magnets' high-temperature stability without compromising on the maximum energy product, thereby reintegrating the precious Nd-Fe-B alloy back into the value chain. This investigation was conducted in the frame of the INSPIRES project.

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