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Iowa State University and Ames Laboratory researchers have developed a method to produce sintered, final-shape magnets with high density and aligned microstructure.  The resulting permanent magnets feature higher energy product and improved remanence versus standard processing, with improved performance in motors and generators.

Iowa State University and Ames Laboratory researchers have developed a process to create AlNiCo magnets in near final shape with improved energy product and remanence versus magnets produced without using directional solidification or zone refinement.  Magnets resulting from this process are characterized by highly controlled and aligned microstructure in the solid state.  Magnet alloy precursor powder is aligned while being added to the mold, with compression molding locking the aligned particles in place.  The resulting microstructural template for grain growth persists through a thermal de-binding treatment and sintering of the magnet.

Magnets produced by this molding process display enhanced energy density, as well as optimized coercivity and magnetization, and have the potential for high volume manufacturing because they are manufactured in near-final shapes.

• Near net-shape production of permanent magnets with high anisotropy and energy product.

• Compatible with techniques to enhance alignment through application of uni-axial loading during sintering.

• De-binding and sintering removes binder material, leaving a highly-dense anisotropic sintered magnet.

Permanent magnets, especially for motors and electrical generators.

Patent(s) applied for