Projects

A Technology Roadmap to Reduce Cost in Performance Materials: reduction, refinement and substitution

Barely a decade after the 2011 Rare Earth crisis, the world entered a second black swan event in the form of the Covid-19 pandemic. It fueled supply chain disruptions and threats of regional strangulation of critical materials o Europe and the Americas. Yet, the demand for NdFeB materials continues to surge with the growth of: high-efficiency motors, mobile consumer electronics, Electric Vehicles and clean energy solutions. Solutions to curb the dependence on both Light Rare Earths and Heavy Rare Earths, has primarily driven the advancement of NdFeB materials and their performance.

We review a variety of parallel technological strides in material advancements by Yunsheng to optimize performance, reduce dependence on LRE and HRE, and enable costdown in magnet cost. We will investigate the latest production-ready technologies being used. These technology solutions include: grain refinement, ternary Rare Earth material substitution, HRE-free and low-HRE materials, and Grain Boundary Diffusion (GBD) technologies.

Bonded Samarium Iron Nitride – A Case for Automotive Usage

Through the development of improved oxidation-resistant coating technology, Nichia has been able to create a SmFeN PPS resin-bonded magnet with the best long-term durability among rare-earth bonded magnets. Automotive applications, in particular, require PPS resin bonded magnets with superior reliability for long term usage. Nichia’s PPS SmFeN magnetic materials can achieve an irreversible flux loss of ≤3% in air at 150°C and aqueous solution at 120°C, making it suitable for harsh environment applications such as water pumps, oil pumps, and fuel pumps. Elevated conditions of greater than 300°C are required for PPS molding, during which magnetic powder can oxidize and degrade if not protected appropriately. Nichia will discuss the performance against currently used bonded Nd PPS materials through various comparisons.

Case studies: Optimizing the magnetic quality of the Formula Electric Belgium and the Innoptus Solar Team electric race cars

As a proud sponsor of both the Belgian Formula Student and the Belgian Innoptus Solar electric race teams, Magcam has effectively employed its magnetic field camera technology and application expertise to enhance the performance of the permanent magnet rotors used in the electric motors in their respective electric race cars.

The Formula Electric car is powered by four radial-flux motors, whereas the Innoptus Solar car operates with an axial-flux motor. In both scenarios, we started the optimization process by measuring a large quantity of individual magnets using our magnetic field camera scanner. From the resulting magnetic field maps, detailed quality parameters were extracted, including overall magnet strength, magnetization angle error and localized magnetic homogeneity. By ranking these magnets based on the derived quality parameters, we were able to select the highest quality magnets for rotor assembly. This first crucial step assures that only qualified magnets are used. The assembled rotors were subsequently measured by Magcam's advanced radial/axial-flux rotor scanner.

Developing the North American permanent magnet supply chain for energy technologies:
Industry and government perspectives

This panel discussion will focus on both government and industry efforts to develop a robust North American supply chain of permanent magnets to support the energy sector industrial base (ESIB). Rare earth magnets, such as sintered neodymium-iron-boron (NdFeB) magnets, are especially important to the ESIB as they are critical components of traction motors in electric vehicles and direct drive generators in offshore wind turbines. Yet, nearly all supply chain stages of sintered NeFeB magnets are concentrated in China, posing a potential vulnerability for ESIB supply chains required to meet climate goals.

Moderator: Braeton J. Smith, Argonne National Laboratory

Panelists:
Helena Khazdozian, Advanced Manufacturing & Materials Technology Office, U.S. Department of Energy
Salim Bhabhrawala, Critical Materials Program Manager, Office of Manufacturing & Energy Supply Chains, U.S. Department of Energy
Alan Lund, MP Materials
Frank Johnson, Chief Technology Officer, Niron Magnetics

Discovery of rare-earth lean high-performance hexaferrites to neo-magnets

We present here our newly discovered crystallographic site substituted high-performance hexaferrites to rare-earth cobalt to neo magnets applicable in vehicle, wind turbine, magnetic cooling, and other household technologies.

The research is supported by the Critical Materials Institute, an Energy Innovation Hub funded by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Technologies Office.

Disrupting the Rare Earth Monopoly: Chromatographic Separation Powering Magnet Circularity

ReElement Technologies, a next-generation rare earth refiner, offers a truly circular solution for rare earth elements. The company uses chromatography, a specialized hydrometallurgical processing technique, to produce high-purity rare earths efficiently and economically to meet domestic and global demand. Traditional refining methods replicating the Chinese model require significant capital and times commitments to deploy, in addition to the associated environmental costs.

ReElements approach is adaptable, scalable and modular allowing for rapid deployment alongside existing mining or manufacturing operations. ReElement’s seamless integration into the magnet supply chain offers manufacturers a sustainable, domestic, and economic source of high-purity rare earth elements for critical applications in aerospace, semiconductor manufacturing and national defense.

Empowering Tomorrow: Trends in Electric Motor Control

Electric motor control is at the heart of various industries, from automotive and manufacturing to energy efficiency and home automation. This panel session will bring together key stakeholders from the electric motor industry – motor manufacturers, chip makers, and analysts – to discuss the latest trends, innovations, and market dynamics that are shaping the future of electric motor control.

Experimental Comparison Between a MOSFET and GaN FET Inverter for Agricultural Drone UAV’s

Battery-powered UAVs are revolutionizing today’s agriculture where they are used to spray fertilizers and more. These drones use motor drives that need to be lightweight and efficient to maximize working battery life and extend flight time between recharging. Wide-bandgap devices, and specifically Gallium Nitride (GaN) FETs, have demonstrated to improve BLDC motor drives in emobility and robotic applications. This paper will present the characteristics of GaN FETs that reduce weight and improve the motor drive system efficiency.

Government Efforts Towards Securing a Clean Energy Supply Chain

Helena will provide a full-scale picture and analysis of the domestic and global investment climate surrounding the clean energy transition. His presentation will focus on U.S. government investments in critical materials, private domestic supply chain investments, and how the U.S. Government is addressing critical material supply chain shortfalls from both the domestic and international allies perspectives. Mr. Bhabhrawala will also highlight other global efforts to mitigate energy sector industrial base supply chain vulnerabilities.

Happy Hour Reception

Join us in the exhibit hall for a happy hour reception. Enjoy complimentary refreshments and Hors d'oeuvres. Take this time network with the exhibitors and connect with fellow attendees via the 1:1 Meeting Program.

How high-temperature superconducting magnets could unlock the energy source of the future

Since the fusion ignition breakthrough at the Lawrence Livermore Laboratory in late 2022,
billions of dollars have been funneled into achieving commercial fusion energy at scale and international
sprint has ensued to be the first company to achieve it. As a clean, limitless energy source, fusion could
solve the world’s energy problems and make today's climate change debate moot. Yet, to achieve
commercial fusion energy at scale, the world needs more of a critical component that is in short supply -
high temperature superconducting (HTS) magnetic wire. HTS magnetic tape is the only material that can
generate a strong enough magnetic field to achieve fusion energy in a device that is substantially smaller
than alternative technologies. This keynote talk will cover how the latest advancements in HTS magnets
are impacting the race for fusion energy and how one community aims to create an ecosystem to
support technological advancements in HTS magnets.

Inferior performance of electric motors caused by degradation of stator magnetic properties after manufacturing processes

This presentation intends to delve into the subject of post-manufacturing degradation in the magnetic properties of stator cores. The analysis is based on evaluations carried out using Brockhaus measurement systems. Additionally, the presentation will explore the direct correlation between the deterioration in magnetic properties and the inferior performance of various types of electric motor topologies. This discussion can shed light on the importance of maintaining the quality of stator cores to ensure optimal electric motor performance.

Iron Nitride – The First New Permanent Magnet in 30 years

ron Nitride permanent magnets have been recognized as a potential breakthrough for the industry. Based on the α”-Fe16N2 compound with high saturation magnetization (exceeding that of NdFeB) and a moderate magnetocrystalline anisotropy, the material pairs technical benefits – attractive magnetic performance and superior temperature stability to NdFeB – with the strategic benefit of being completely rare earth-free, relying instead on abundant commodity raw materials. Iron Nitride will act as an economical substitute for several grades of both sintered and bonded NdFeB magnets. Further, they offer significant advantages in terms of environmental footprint and recyclability.

Niron will address the background of the material, selections of the latest empirical data, implications for device design, and details on the process being taken with industry players to commercialize the first new permanent magnet in over 30 years.

KetaSpire PEEK for insulation of magnet wire and slot liners improves performance of 800V+ eMotor systems.

For eMotor designers, seemingly small improvements in power and efficiency can have real-world tangible benefits like weight reduction, increased range, and cost savings. Optimizing the insulation materials in an eMotor is just one of the ways that can help design engineers reach their performance targets. Extruded KetaSpire® PEEK for magnet wire insulation and Ajedium PEEK slot liners have garnered significant attention in recent years as more sustainable and higher performing alternative insulation systems versus their incumbent counterparts, enameled wire and aramid papers.

In this presentation, we will show how the use of PEEK materials over traditional enamel magnet wire and aramid papers allows for reduced bill of materials across the electrified powertrain.

Keynote: Magnet supply chain resiliency and transparency

Moderator: Jeff Whalen, Founder & Director, MagCorp

Panelists:
Chris Rainone, Global Supply Chain SME for Critical Materials & Supply Chain, Lockheed Martin
David Miller, President, Magnetic Instrumentation
Helena Khazdozian, Senior Technology Manager, Advanced Materials & Manufacturing Technologies Office, U.S. Department of Energy

Lunch Reception

Please join us for a full buffet Lunch Reception. Keep the conversations going over a delicious lunch.

Magnet Bonding Adhesive Technology for High Performance and High Throughput Processes

Henkel has been a leader in developing magnet bonding adhesives for many years. Magnet
bonding is used in a wide range of industries, including electrical machinery, power tools, the
automotive industry, audio and video equipment, household appliances, and others. The
production of electric motors specifically relies on adhesives to enable robust and reliable
magnet bonding. Henkel offers a comprehensive line of LOCTITE® magnet bonding adhesives
specifically formulated to withstand the stresses and environmental extremes seen in a wide
range of magnet applications. Major trends in the electric motor industry include
miniaturization and weight savings, all while producing the same or higher efficiency motors.
Motor manufacturers are moving to internal permanent magnet designs that require a unique solution for magnet retention. Henkel’s adhesive solutions enable high performance and high-
speed processing for IPM designs where other conventional methods are insufficient.

Henkel is also developing new adhesive solutions to match the changing industry trends as magnet
bonding applications require higher-temperature resistance and faster fixturing for high-speed
processing.

Magnetic Simulations and Measurements for Designing Stray Field Robust Sensors

The presentation will comprise the development of two stray field immune magnet-sensor systems. It will cover the methods in their pre-design process as specific FEM simulations and 3D-Hall sensor measurement before realizing any hardware. Stray field immune sensors are often built by sensor pairs using the gradient principle. So, first stage tests including simulations and Hall measurements on different traces close the magnet and calculating potential sensor pair outputs are very valuable. Both can prove the viability of a devised systems and when successful the practical realization can be initiated. The whole way from pre-design investigations up to the hardware realization of a first sensor will be sketched in the presentation.

Mastering Litz Wire: Winding and Welding Techniques for Enhanced Performance

This presentation commences with an introduction to Litz wire by Mr. Benjamin Braggins. He will explore various types of Litz wire, discuss VDE and UL certifications, cover coating options such as serving and taping, and provide valuable insights into the best design practices for electric motors and magnetic components. Mr. Rajasekhara will continue highlighting the main obstacles in winding and welding processes that involve litz wire and how they can be overcome. From how to control tension to get perfect layering despite the variable morphology of the wire, how to avoid wire untwisting, up to how to get clean and solid wire/terminal welding points with wire with high thermal class and composed of many tiny, twisted wires.

Materials, Automation & Simulation in Electric Machine Design & Production:
Magnetic Orientation Technology – Radial AND Multipolar and Applications

Proper application of magnetic materials requires attention to several factors including benchmarking, material considerations, assembly techniques and design optimization. Using radial NdFeB ring magnets in permanent magnet motors provides a cost effective and simplified assembly method to improve motor performance while increasing production yields. This presentation will focus on design considerations and assembly methods using patented radial ring magnets that improve balance, while reducing noise, vibration and cogging torque.