Composite Magnetic Materials for Machinability
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Solution Overview
Problem
Magnetic materials like Nd2Fe14B, Sm2Fe17N2, Sm2Co5, and Sm2Co17 suffer from poor mechanical properties due to their intermetallic nature, making conventional machining difficult and requiring specialized manufacturing methods, while also being prone to corrosion.
Innovation Solution
A magnetic material comprising a combination of metallic phases (transition metals, post-transition metals, and alkali earth metals) with a magnetic phase, processed using a method involving pressure and voltage application to create a composite with enhanced mechanical and magnetic properties, allowing for machining with conventional tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If intermetallic magnetic materials (Nd2Fe14B, Sm2Fe17N2, Sm2Co5, Sm2Co17) are used to achieve high magnetic properties, then magnetic performance is improved, but mechanical properties deteriorate and conventional machining becomes difficult
Solution Approach 1:
The patent applies composite materials by combining intermetallic magnetic phase particles (Nd2Fe14B, Sm2Fe17N2, Sm2Co5, or Sm2Co17) with a metallic binding phase to create a composite structure. The magnetic phase provides high magnetic properties while the metallic binding phase provides mechanical strength and machinability, resolving the contradiction between magnetic performance and mechanical properties.
Solution Approach 2:
The metallic binding phase acts as an intermediary between the magnetic phase particles, providing a matrix that holds the particles together and enables conventional machining. This intermediary phase transfers mechanical loads and allows the use of standard cutting tools while preserving the magnetic properties of the embedded particles.
2Reliability
If sintering method is used to manufacture high-performance magnets, then magnetic properties are improved, but manufacturing complexity increases due to multiple sequential operations
Solution Approach 1:
The patent merges the magnetic phase particles with the metallic binding phase into a single composite material system that can be manufactured in one sintering operation. This combines what would traditionally require separate steps for creating the magnetic material and providing mechanical support, simplifying the manufacturing process while maintaining high magnetic properties.
3Ease of manufacture
If conventional cutting tools are used to machine intermetallic magnets, then ease of machining is improved, but the intermetallic nature prevents effective machining
Solution Approach 1:
The metallic binding phase serves as an intermediary that enables conventional cutting tools to effectively machine the material. The ductile metallic phase allows chip formation and tool engagement, while the embedded magnetic phase particles maintain their composition and properties, resolving the contradiction between machinability and compositional stability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting composite magnetic material achieves high magnetic properties and improved mechanical strength, enabling machining with steel and hard metal tools, while maintaining magnetic performance and reducing corrosion susceptibility.
Implementation Method 1
the metallic phase(s) providing good machine processing capabilities
Implementation Method 2
the magnetic phase(s) achieving 'hard' magnetic properties, i.e. the capability of retaining magnetic field
Implementation Method 3
reducing corrosion susceptibility
Data Source
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AI summary
Disclosed herein is a magnetic material comprising at least one metallic phase and at least one magnetic phase, each metallic phase comprising one of: - a transition metal or alloys thereof, - a post-transition metal or alloys thereof, and - an alkali earth metal or alloys thereof, each magnetic phase comprising one of: - a magnetic alloy having the formula RE2TM14B, - a magnetic alloy having the formula Sm2Fe17NxCy with 0<=x<=3 and 0<=y<=3, preferably x=3 and y=0, - a magnetic alloy having the formula SmFe7NxCy with 0<=x<=1 and 0<=y<=1, preferably x=1 and y=0, - a magnetic alloy having the formula RE'2TM'1-7 - a magnetic alloy having the formula RE'TM'5 wherein RE is a first rare earth element, RE' is a second rare earth element, TM is a first transition metal, TM' is a second transition metal, B is Boron, N is nitrogen, C is carbon, Sm is Samarium, Fe is Iron, wherein the total amount of the at least one metallic phase is comprised between 25% and 95% in volume of the magnetic material.