Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - AMPHIBIAN (Anisometric permanent hybrid magnets based on inexpensive and non-critical materials)

Teaser

Permanent magnets are crucial in modern technology as they allow storing, delivering and converting energy. They are able to transform electrical energy into mechanical and vice versa, which means that improving their performance entails transforming energy in a more efficient...

Summary

Permanent magnets are crucial in modern technology as they allow storing, delivering and converting energy. They are able to transform electrical energy into mechanical and vice versa, which means that improving their performance entails transforming energy in a more efficient and sustainable way.
The best magnets are based on rare-earths (RE), however, their status as a Critical Raw Material (CRM) has brought forward the realization that it is of great strategic, geographic and socio-economic importance to consider alternative magnets that present a reduced amount (or absence) of RE. One of the most sought approaches towards this goal consists on constructing composite magnetic materials magnetically coupled at the interface.
In the framework of the success of a previous European Project (FP7-SMALL-NANOPYME-310516), focused on improving ferrite-based magnets, we developed a low-cost novel approach (Patent P201600092) that exploits the magnetostatic interactions within these composites and that yielded extremely promising results in the form of an experimental proof-of-concept.
The goal of this project is to implement up-scalable and cost-efficient methods for fabrication of ferrite-based dense anisotropic magnets with a 40% enhanced magnetic performance (energy products above 55 kJ/m3) with respect to commercial ferrites. We aim at producing improved magnets that retain the advantages of ferrites –availability, sustainability, cost, recyclability- and which have the potential to substitute currently used RE magnets in the electric power system.
Our targeted application is an electric energy storage device: we will substitute RE magnets by AMPHIBIAN ones in a demonstrator of a flywheel and evaluate its performance against cost, eco-friendliness and resource efficiency criteria.

Work performed

\"We will briefly summarize the work carried and the main results obtained thus far towards the completion of each of the main objectives and milestones of the project.

“Objective 1: Design and Fabricate high-performance anisotropic dense magnets.”
• We have achieved a state-of-the-art ab initio description of the magnetic properties of the soft and hard bulk ferrites at the atomic level (WP1).
• The conditioning of the individual hard and soft phases has led to competitive properties of the constituent materials (WP2).
• In isotropic composite powders containing 20% Fe and 80% commercial Strontium ferrite, we have observed an increase in remanence. The achieved value of Mr = 51.7 emu/g corresponds to a 27% increase in remanence with respect to commercial strontium ferrite (SrFe12O19), and a 20.4% increase in remanence with respect to the isotropic composite before milling.
• The most promising result of the project so far is that in anisotropic hybrid powders containing soft nanowires as the soft phase we have observed a 47% increase in remanence (WP2).
• In injection molded anisotropic hybrid magnets (WP3), composed of 15% Fe (soft) -85 % SrFe12O19 (hard), we have observed a 15% increase in remanence for equal fillings of ferrite and 10% increase for composites of 15% soft ferrite (MnZnFe2O4) -85 % SrFe12O19 (hard). These results correspond to an overall remanence increase of 4% in injection molded magnets (WP3).
• For sintered magnets, we have reached densities of 98% by conventional sintering and 97% by advance sintering (Spark Plasma Sintering) (WP3).

“Objective 2: Evaluate and assess recyclability, sustainability and life cycle.\"\"
• A general evaluation of safety issues associated with the materials we are currently using for magnet fabrication has been undertaken (WP5). This will be narrowed down once the exact materials and processes are defined.
• A loss of 10% in tensile strength after 10 recycling cycles has been observed.
• We have achieved a full recovery of the magnetic properties of the MB waste after a milling and annealing procedure. The goal is to reduce the temperature at which properties are recovered.
• We are investigating the possibility of reusing the ferrite sprue for the manufacturing of magnetic tiles, in collaboration with the Keraben company.

“Objective 3: Up-scale and test the improved hybrid permanent magnets.\"\"
• The cost of the 7 most promising routes for obtaining improved magnets has been evaluated, in order to factor in this important parameter for narrowing down to 3-4 routes.
• In a first up-scaling attempt, in preparation for the 10 kg powder supply deliverable in M24, 3 kg of a hybrid compound consisting of 15% magnetite – 85% SrFe12O19 have been fabricated at very competitive cost.

“Objective 4: Demonstration of substitution in an energy storage device.\"\"
• We have worked on optimizing the mechanical design in order to reduce the magnetic strength needed to levitate the flywheel.
• By making a mathematical model and optimizing the physical design. We can reduce magnet strength by 30% and still keep sufficient levitation force, while increase stability by 50%.”

“Objective 5: Develop and implement the Exploitation, Dissemination and Communication strategies.\"\"

• We have completed a wide variety of dissemination and communication activities.
• An IPR policy implementation report has been produced.
• The dissemination and exploitation plans have been updated.
• The Data Management Plan is active and currently being deployed.
• The exploitation plan is being deployed, contact with end-users and strategies towards exploitation of the innovations are being pursued, among others: a proposal for a EIT Up-Scaling Project is being prepared, a contract has been signed to develop magnetic tiles for bathrooms/kitchens.

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Final results

The results listed above all correspond to progress beyong the state-of-the-art. The main progress achieved so far with respect to the two main outputs of the project (improved magnets and rare-earth-free flywheel) is a 47% increase in remanence in ferrite-based magnets, in good progress towards the 20% target, and the design of a novel flywheel that needs 30% less magnetic field strength while gaining 50% stability.

In the remaining of the project, we expect to achieve the milestones of the project by:
1. Demonstrating the substitution of rar-earths in a prototype rare-earth-free flywheel
2. Achieving a 40% increase in energy product in prototype ferrite-based magnets.
3. Up-scale and decrease the production cost of the improved ferrite-based magnets.
4. Reduce the temperature required and associated process costs to recover properties of recycled magnets.
5. Maintain the highly active dissemination and communication strategy, with particular emphasis in societal engagement.

The potential impacts of the project remain unchanged at this point with respect to the initial exploitation and dissemination plans. With respect to social awareness/engagement: An active and thorough communication and dissemination is helping raise social awareness on the crucial importance of sustainability and resource efficiency.

Website & more info

More info: http://www.amphibianproject.eu.