Graded permanent magnetic components for resource-efficient use of critical rare earth metals (GradMAG)

Increasing electrification, for example in the mobility sector, and the expansion of wind energy are leading to a growing demand for efficient electrical energy converters. Along with the design, the rare-earth permanent magnets used in these applications are decisive for the machine performance. However, the magnets are subjected to varying loads during machine operation. In order to compensate for operating peaks during overloads, they are often designed with high dimensions - and contain a not inconsiderable proportion of critical and expensive heavy rare earth metals (HRE) such as dysprosium or terbium.

The aim of GradMAG is to produce a tailor-made high-performance permanent magnet that enables a significant saving of the heavy rare earth metals with little additional effort in the production process: Novel permanent magnet prototypes are realized by powder metallurgical co-sintering of graded green compacts from different magnetic powders. They are magnetically reinforced only at points subject to high stress during machine operation. The sustainable and economical magnet and machine design saves resources and reduces CO2 emissions. It is expected that the critical and expensive heavy rare earth metals can be saved by 20 to 50% in this way. The production is carried out in cooperation with a magnet manufacturer.