The Development Of Dy Free MAGFINE And Its Applications To .
Dec. 06 (Fri) Symposium on ‘Current Research Trends in Magnetic Materials’The development of Dy free MAGFINE and itsapplications to MotorsMAGFINE means NdFeB anisotropic bonded magnet produced by d-HDDR process§１§2§3§４§５BackgroundDevelopment for Magfine powderHow to produce Magfine bonded magnetMotor applications of Magfine bonded magnetFuture scopeDec. 6th . 2013Yoshinobu HonkuraAdviser of Aichi Steel Corp.Vice President of Magnetic Society of Japan1
2AICHI STEELTOYOTA Group 15 companiesToyotaIndustriesA TOYOTA Group CompanyEstablished:1940Location: Nagoya, JapanCapital: 25 billion JPYEmployees: 4,406 (total Aichi Group)Annual Sales：227 billion JPY (2012)JETEKTToyota BodyToyotaBoshokuToyota GoseiAICHITOYOTAAisinSTEELＡＩＣＨＩ Group18 subsidiary companiesToyota TsushoToyota R&DHino MotorsDaihatsuＭａｉｎ BusinessDensoKanjiAutoTowaReal Estate-Next Core Business-Sales 13billion yen in 2012-Target : EV motorNd anisotropic Bonded Magnets500ton/ year No.1 share in the worldSpecialty Steel2ndCrankshaftslargest in JapanGearsStainless SteelShapesNo1 share in JapanForged Parts forAutomotive industryThe world’s mostfrom a single plantMagnetic SensorsHeatsink part for EV car100% Share of TOYOTA2Dental Magnet AttachmentNo1 share in the world
3MAGFINE production processNdFeB anisotropic bonded magnetCompression molded magnetMagnet PowdercompoundRing magnet Press fit to PHresin(BH)max：43MGOeMagnet powder(BH)max epoxy resinthermo setting resign 18 23MGOeMAGFINE powderInjection molded magnetpelletMagnet powder thermo plsticityresign3Direct injected to motor Rotor(BH)max10 17MGOeMotor
The development of NdFeB anisotopic magnet powder4Maxmum Energy Product(BH)max / MGOeBonded magnet with BH max of 20 and good formability must be desired for ideal motor design.MAGFINE powder was developed in 2000 and improved up to 43MGOe with the coecivity of15KOe. This performance is almost same to Nd sintered magnet.MAGHEM projectFor Next Generation magnet60Nd2Fe14BSintered magnet50Coecivity of 15KOeNd Sinterd Magnet3rd generation MF2nd generation MF401st generation MFSm2Co1730InicialHDDRpowderSmCoAnisotopic NdFeBMagfine powder)Aniso-NdFeBbond magnet（Magfine)520Bonded MagnetMQ Powder10KSSteelAlnicoFerrito sintered Magnet01900Iso-NdFeB bond magnetFe-Cr-CoMK19301960199020０0 １020year
the Yamazaki Teiichi Prize in 2012山崎貞一賞 The Yamazaki Teiichi prize given byFoundation for promotion of Material Science and Technology of Japan,TitleThe development ofDy free NdFeB anisotropic bonded magnet and its motor applications5
Dec. 06 (Fri) Symposium on ‘Current Research Trends in Magnetic Materials’The development of Dy free MAGFINE and itsapplications to Motors§１§2§3§４§５BackgroundDevelopment for Magfine powderHow to produce Magfine bonded magnetMotor applications of Magfine bonded magnetFuture scope6
7Phase diagram on HDDR-process（Hydrogenation Desproportionation –Desorption Recombination）NdFeB H2Coarse grain100μｍNdH2 Fe Fe2BHDDR840 3KPa840 ３０KPa1173Step 3:Nd2Fe14B1 HxStep 4:Nd2Fe14B11073DecompositionmicrostructureStep 2:NdH2 Fe Fe2BDRHD9738730 Step ５：Nd2Fe14B110-3Step 1Nd2Fe14B1 Hx Temperature ( K)1273NdFeB H2Fine grain0.2μｍ0.1H2 Pressure110100 1000( kPa)recombinationNd2Fe14B
History of the development of NdFeB anisotropic powder8First challenger was GM. GM successfully developed it n 1998 using die upset method but GMgave up the development in 1995 because of high cost.⑦after 2015年 愛知製鋼challege to improve anisotoryto 55MGoeNd sintered magnet⑦10⑥⑤④磁化 (M /KG )15⑥2010年 Mr. Honkura（愛知製鋼）Discover Dy-free by diffusin processto 42MGoe⑤2000年 Mr. Honkura（愛知製鋼）Dicsover d-HDDR to 40MGOeIn 1996 deiscover d-HDDRNd等方性磁粉 15MGOe④1995年 Mr. Takeshita（三菱material）Improve to 33MGOe by Ga,Zr addition③③1990年 Mr. Takeshita （三菱MaterialDiscover anisotropic HDDR by Co addition17MGOe②5NdDy sintered magnet①②1989年 Mr. Takeshita （三菱Maerial）discover isotropic HDDR①1985年 Mr.Inoue（並木精密）First discover HDDR phenomina not perfect-20Magnetic field-15(kOe)-10-500
9Previous research on HDDR phenomena（Hｙdrogenation-Disproportionation Desorption Recombination)In 1992 Anisotropic powder of NdFeB alloy was found by Co additionThis is mysterious phenomena , because recrystallization structure is isotropic .absorptionNd2Fe14B H210αFe NdH2 Fe2Bdesorption9.0Br /kGgrain size of 0.2μm from 100μmCo cotainig NdFeB alloyanisotropic8.0NdFeB alloy isotropic7.0T.Takeshita and R.Nakayama12th REPM (1992) 670Nd2Fe14B200nmNd12.6Febal.CoxB6.06.001020Co element /at%930
New phenomena in Co less NdFeB alloy discoveredby Aichi Steel in 1996 named as d-HDDR process50(BH)max (MGOe)Anisotropy40Drastic change30desportion1kPa of H2 pressurefinal pressure1Pa of H220Isotropy100absorption30kPa of H2 pressureNd12.5Febal.Ga0.3Nb0.2B6.4 Without Co020406080100H2 pressure / kPa on absorption 10process10
11Effect of Co element on anisotropy or isotropyCo 0%(BH)max/MGOe40Co 17%30201000.51.01.5Hydrogen pressure, PH2/atm2.011
Effect of alloy elements to magnetic properies18 Additive elements (Al,Si,Ti,V,Cr,Nb,Mn,Ni,Cu,Ga,) were tested.Ga can improve coecivityNb can improve Br , which means to improve anisotropy1212
13Alloy design for MAGFINE powderAlloy design :Nd12.5 Febal.Ga0.3Nb0.2B6.213
Hipothesis on the mechanism how to make anisotropyHypothesis in 1996NdFeB H2Coarse grainTetragonalC: easy axisNdH2 Fe Fe2BｆｃｃisotropicNdFeB H2Fine grainｂｃｃTetragonalisotropicC: easy axisTetragonalC: easy axisIn 2004 we found good aliment of Fe2B phase by TEM observation and proposed thismechanism named as Texture memory effect.NdH2Fe2BFeFe2B100nmFe2B14
Development for2ndgeneration : Dy free Magfine powderNew idea for improving the Coecivity without Dy and Ga additionDy diffusion10Current HDDR②①Ga addition5StoichimericGa lessNdCuAl diffusion③④0NdCu diffusion-20-15-10-50Magetic field H / kOe③④Honkura： 09年12月出願 Patent 2009-279314magnetization M / kOe15ＮｄＦｅＢNd2Fe14B1stoichiometricC axis Ga lesscompositiond－HDDR processAnisotropic fine grainwith no boundary phaseNdＣｕＡｌ alloy diffusionNd rich grainboundary15
16Effects of diffusion elementsNd only50Ti Cr Mo Mn Co Ni Cu Al GaAdditional element（X)Nd80X2016Si60 40 20 0Nd100Nd-Al128100AlNd80Al20105Treatment conditions:800 1hr002468Addition ( wt%)40Nd80Cu20150100Cuas d-HDDR powderTernaly alloy of NdCuAlCombination effect of cu and Al20Nd80Cu10Al10target84iHc /kOeiHc /kOe10iHc /kOe15NdFeNbB（95wt%) NdX (5wt%)Diffusion process：800 deg.C 1hrBinaly alloy of NdCuand NdAl16Nd-Cu12iHc / kOeBinaly alloy with additionalelement of 5wt %60 40 20 0Nd10010
17Why NdCuAl diffusion can increase the corecivity ?TEM( Trans-Electron-Microscope) observation make clearAfter HDDRAfter diffusion of Nd Cu Al alloyNdWithoutBoundary phaseNd concentrationon the boundarywide boundaryphase100100 nmnm100100 nmnmG.B (B)５ nm５ nmGrain (A)CuCu concentrationon the boundary
Coecivity iHc（KO e）The effect of the boundary phase width on the coecivity20100024Width of boundary phase （nm)618
19Alloy design for Dy free MAGFINE powderAlloy FeNbB 3％NdCuAl43MGOe15 kOe13.8kGMF-18PNd27.5FeNbB 6％NdCuAl38MGOe18 kOe12.8kGcomparison of magnetic properties with various magnets10Sintered magnetsNew magfineIsotropic powder5Ferrite magnets60(ＢＨ)ｍａｘ/ＭＧＯｅBr /kG15Sintered magnets504030New magfine20IsotropicpowderFerite magnets100001020iHc /ｋＯｅ3001020iHc19 /ｋＯｅ30
Dec. 06 (Fri) Symposium on ‘Current Research Trends in Magnetic Materials’The development of Dy free MAGFINE and itsapplications to Motors§１§2§3§４§５BackgroundDevelopment for Magfine powderHow to produce Magfine bonded magnetMotor applications of Magfine bonded magnetFuture scope20
21Magnetic properties of MF magnet(compression & injection)601625 MF bond magnetcompression/kG3020Nd sintered ＭＧＯｅ4014Nd sintered magnet5025 8MF bond magnetcompressioninjection6Nd Isotropic bond magnet410injectionNd Isotropic bond magnetferrite2ferrite0010020Coercivity (ｋＯｅ)30051015Coercivity 21(ｋＯｅ)2025
22reliability of injection molded magnet compared to compression typea) oxidation （under 150 ）1) compression-5Ratio of demagnetization( %)Ratio of demagnetization( %)0specificationPc 2.0-10Dy free Magfine （’10）Previous Magfine （‘07）110time / hr1000specification-5Pc 2.0-10MQ-150b) corrosion （under 80 , 95%RH)Without surface coating1000-15011010010000-5Ratio of demagnetization( %)2) InjectionRatio of demagnetization( %)time/ hrspecificationPc 2.0-10Dy free magfine （’10）MQ-150110time / hr10010000specification-5Pc 2.0-10-15012210100time / hr1000
Dec. 06 (Fri) Symposium on ‘Current Research Trends in Magnetic Materials’The development of Dy free MAGFINE and itsapplications to Motors§１§2§3§４§５BackgroundDevelopment for Magfine powderHow to produce Magfine bonded magnetMotor applications of Magfine bonded magnetFuture scope23
24Trends of Automotive use motor①manual operation Small motorBrakeHEVFuture outlook report 2011-2025Automotive industry Nikkei BP consulting Mr.Sakae TanakaOutlook 10K/year(20kton/year)Power windowWiper2 billion pcsSeatCooling fanSun roofVVTPre-crashABSSlide doorFuel pumpDoor ditionerEPS③Engine Main motor(20kton/year)②Hydrolic power Power motor(20kton/year)Increase of motor numbers perone car400020000200020052008201520202025Car Production will be doubled in 2020・Increasing mainly in emerging countries・Advanced countries may keep the current level.
First MAGFINE application to small DC brush motor with 40wMAGFINE seat motor for seat1n 2013In 2005140ｇ235ｇFerrite seat motor465gWeight reduction40%Weight reduction50%Rotation speed3000 6000rpm465ｇ4 pole4 pole2 Ferrite magnet Axial alignmentSNMAGFINE magnet(BH)max:20MGOe4 pole alignment with radial alignmentN80ｇ t 5mmSSN23ｇ t 1.5mmNSSN8ｇ t 1.0mm25
26Performance of Seat motor50% Lighter 50W Motor for AutomobilesApplications for 1mm-ring MagnetProposalChange 2-pole sintered ferrite magnet to 4-pole MAGFINE 1mm thickness magnetPerformanceTorque 20% / Max efficiency 15% / 10% lower cost (Aichi Steel estimate)ApplicationsPower seat motor etc.No.01NMotor body φ 45xL68mmMotor weight 465gFerriteMagnet weight 80gMotor body φ 37xL38mmMotor weight 235gMF14C(4-pole semi-radial alignment)Magnet weight 16gRPMEfficiencyMAGFINE1mm-ring magnetTorqueT
27Extension of weight reduction MF motors Modular system using common motor with 30w ABS motor by Bosch100w・ Ｓｅａｔ / Wiondow / Sunroof / Rear Wiper Power Tool of Makita300W50WIn 2006TOYOTA development award100WIn 2010Bosch Innovation Award（
28YAMAHA developed E-bike motor using MAGFINEMax power of 1.4Kw with Flat shape motorby using injection molded MAGFINE with 12-polest 3mm130mm190mmRated power:600W，Max. power 1.4kW28Injection molding：MFP15 Magnet weight：277g
Develop Dy free MF motor for Compressor with 1 kwDy-Nd Sint. magnetＩｔｅｍBr:13kG, iHc:21kOe4pole-6slotMAGFINE MF18P(PPS) Br:8.2kG, nRating torque(@4Arms, 3600rpm)Rotor outer diameter DRotor length L3Nmφ50mm35mm3Nmφ50mm45mm (30%up)3Nmφ60mmφ60mm35mm35mm3.3mm2.8mmMagnet thickness tm2.7mmMagnet weight70g(1.0)150g(2.1)130g(1.8)105g(1.5 )Nd 21, Dy3.5Nd 45Dy0Nd 39, Dy0Nd 32, Dy0(CR, comparison ratio with Nd sint.)Rare earth weight (g)4.5mm3Nm29
How to design power motor using Dy free MAGFINE withlow coercivity of 18Koe80% Under limitationOperation atcurrent of 0 A14Guideline of MF motor.High permiance ofmagnetic circuitIncreasing �磁石（安定化処理後）64 Magnetic flux density B（kG）Nd sintered magnet with Dy121)2)3)4)multi- pole structure.reluctance torquesuitable curve shapedemagnetizationof electromagnet5) cost competition .2120 120 0-12-10-8-6-4-20M agn e t i c fi e l d H（ kOe ）3030
IPM motor design with the power of 5Kw or 30KwTorque Ttotal:13Nm(Tm12.4, Tr 0.6(5%))VUVWWDyNd sint.240g（Dy5%)VUWVWVUTorque Ttotal:13Nm(Tm11.2, Tr 1.8(14%))UUVWWRotor diameter 76ΦUMF430g（2times)UWVRotor diameter 100ΦDy free MF motor8p-12slotDyNd sint. motor6pｰ9slotMagnet torqueReluctance torque31
New proposal to innovate the motor design using MAGFINE32Dy free Nd bond magnet with coecivity of 18KOe can make EV motor design due to optimal designincrease of magnet poles , two layer magnet structure and increase of rotor diameterNd sintered magnet80KwEV5kW motorE-bike1010.1Kw Small motor0MAGFINENd anisotropic bond magnetDy free MF100Motor power P (kW)by1015８ poles６ poles1kw motorCompressor2025Coercivity (kOe)Dy content increase 10 16 poles８ １２poles４ poles30NS２ poles８ poles４ polesNSSN
Dec. 06 (Fri) Symposium on ‘Current Research Trends in Magnetic Materials’The development of Dy free MAGFINE and itsapplications to Motors§１§2§3§４§５BackgroundDevelopment for Magfine powderHow to produce Magfine bonded magnetMotor applications of Magfine bonded magnetFuture scope33
34Resources of Energy and rare metal meet shortage .Trends of oil priceDollars/Barrel１） oil price Increases rom 25 to 100 ２） Worry of Rare earth supply chaindue to monopoly production of ChinaNd price : 30 /kg 300 /ｋｇDy price : 10 times larger to Nd)100 25 19931983Location of rare earth mines350Crazy price of NdyearCrazy price ofDyInternational4000300 3000 2/5UPDATEDomestic China3000( /kg )25020015010050Dy2000Price（US /kg）300Nd metal20132003100020-30 ７0 0775Nd01471014710'02.4 '03.4 '04.4 '05.4 '06.4 '07.4 '08.4 '09.4 '10.4 '11.4 '12.4 '13.4201120131
Improvement of the motor efficiency from the loss of 30% to 5% will be achieved 35by developing PM motor system with the high rotation speedTrend of high rotation speed motor・EV motor:: 6K 13.5K RPM 30Ｋ ＲＰＭ・ Cleaner : 30K 100K RPM・small motor 3K 30K RPMElectric EnergySourceIGBT of SiCHow to achieve１）developmet of new materails・magnett :: NdFeB anisotropivcbonded magnet)・yoke :: SMC with nano cryatallineFe powderPower controllerMAGFINESMCReactorSmart gridMotorComputerGear Box２） new design for PM motor with highrotation speed・EV motor・reactor・magnetic gearBatteryFuel cellGeneratorMagneticGear bearingSensornetworkRotation Energy output
Next generation EV motor using 3rd generation uture motor withRotation speed of30Krpm from15KrpmAchieve 50% downsizingHighfreedomof motordesignNdsintered magnet：766gCost of Nd 10Dy : 590 Magfine：1480g（1.9 times）Cost of Nd 10Dy : 444 When 3rd generation Magfine will be developed,Future EV motor with High speed rotation must use 3 rdgeneration MAGFINE instead of Nd sintered Magnet18211336
37Demagnetizing of magnets under high frequency magnetic fieldBrOperating pointKnick pointamplitudeCoecivityｂHc Hk０Magnetic field （KOe)5 ＫＨｚ10 ＫＨｚ0.5 KOe0.5 KOeBrOperating pointKnick pointCoecivityFlux dencity （KG)0.5 KOeFlux dencity （KG)1 ＫＨｚamplitudeｂHc Hk０Magnetic field （KOe)BrOperating pointKnick pointCoecivityFlux dencity （KG)DC reverse field of 3KOe, 1KHz of 300 Oe , 10 KHz of 300 OeDependency on the frequencyamplitudeｂHc Hk０Magnetic field （KOe)Dependency on the magnetic amplitudeKnick pointCoecivityｂHc Hk０Magnetic field （KOe)amplitudeBrOperating pointKnick pointCoecivityｂHc Hk０Magnetic field （KOe)amplitudeBrOperating pointKnick pointCoecivityｂHc Hk０Magnetic field （KOe)Flux dencity （KG)5 ＫＨｚ5 ＫＨｚFlux dencity （KG)BrFlux dencity （KG)5 ＫＨｚOperating point1.0 KOe0.5 KOe0.25 KOeamplitude
38Method for measuring the demagnetizing under high frequency magnetic fieldExciting CoilvibratedExciting CoilstaticEquipmentFlux meterSample size：７ｍｍΦ ７ｍｍfrequency 0 10KHｚamplitude ０ 0.5KOeStatic field 0 4KOeFlux coilHall elementSampleAnnaliseFor BH curveHall sensorCondensorEvaluationOscillation sourceExtend the minor loopamplitude Hａ （ＫＯｅ）1.6Demagnetizing area ｂHc０Magnetic field （KOe) 1.0Ｈｆ0.8 ＠１ＫＨｚＨｆ0.6＠5ＫＨｚ etic field （KOe)２．４ＫＧ１０５Vibrated on the recoil line0.25 KOe5 ＫＨｚStable area０0.5 KOe5 ＫＨｚ３．３ＫＧ0.40.2Appear the minor loopOperatingpointBrFlux dencity （KG)OperatingpointBrFlux dencity （KG)1.0 KOe5 ＫＨｚFlux dencity （KG)Magnetic fatigue strength indexed byfrequency is defined as the upperlimitation not to extend the minor loop１０７Frequency number N（times）ｂHc０Magnetic field （KOe)
39Discussion on the magnetic fatigue strengthWhy magnetic fatigue strength is smaller than coecivity ?・Heated surface by eddy current makes reverse magnetic domain easy under weak magnetic field.・The wall of reverse magnetic domain is vibrating by frequented field to make local heating zone.・These heating extend the reverse magnetic domain to make minor loop growth. HdomainsurfaceCrystal grainHeating on the surface-HMagnetic fatigue strength (Oe）Nd anisotropic bonded magnet is expected to have better magnetic fatigue strength than that of Nd sintered magnetbecause・ have 1000 times ｂｉｇｇｅｒ resistance・ have 10,000 times smaller crystal grain sizeImagination result８00Nd anisotropic bonded magnet５00４00Nd sintered magnet３00２00１00Vibration zineHeating at location００246810Frequncy of magnetic field ｆ（KHz）
40Introduction to Energy Magnetics Study Group of MSJ1）New strategy of MSJ is to challenge Energy field.Target is to reduce Energy Loss from 30% to 5%２）Progress・Sep. in 2013 Symposium・Dec. establish the study group・next June hold the meeting３）topics①develop new magnet and magnetic materailElectric EnergySourceIGBT of SiCimprove basic performance and magnetic fatigue strength②Mechanism by micro-magnetics analysis③How to design high speed rotation EV motor④make new design of Transformor・magnetic gear and bearing・reactor⑤develop base R&D technique・FEM analysis treated high frequency fenomina・Equipment and deta base⑥MEMS generatorBatteryFuel cellGeneratorPower controllerMAGFINESMCReactorMotorGear BoxMagneticGear bearingSmart n magnetic societies・Electrical Engineers of Japan and The Japan Society of Applied PhysicsRotation Energy output
Summary（1）develop Dy free Nd anisotopic bonded magnet（2）develop the mass production technology of Magfine・d-HDDR furnace・micro capsule・press molding・injection molding（3）develop new designed motor using MAGFINE・75% weight reduction small motor for automotive use・IPM motor using Dy free MAGFINE for compressor・Axial motor for Electric bike（4）Challenges to new research・develop 3rd generation type of MAGFINE by achieving perfect anisotropy・improve motor efficiency for developing high speed rotation motor・research demagnetizing under high frequency strong magnetic field41
4242Thank you for your attentionMt. Fuji
Steel KS MK Alnico Fe-Cr-Co Iso Ferrito sintered Magnet -NdFeB bond magnet Aniso-NdFeB bond magnet （Magfine) year 0 20 MGOe Nd 2 Fe 14 B Sintered magnet Sm 2 Co 17 SmCo 5 60 . Sun roof ①manual operation Small motor (20kton/year) (20kton/year) (20k
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Le genou de Lucy. Odile Jacob. 1999. Coppens Y. Pré-textes. L’homme préhistorique en morceaux. Eds Odile Jacob. 2011. Costentin J., Delaveau P. Café, thé, chocolat, les bons effets sur le cerveau et pour le corps. Editions Odile Jacob. 2010. 3 Crawford M., Marsh D. The driving force : food in human evolution and the future.
