NdFeB Magnet Composite Plating for Corrosion Resistance
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Solution Overview
Problem
Conventional surface treatment methods for NdFeB rare earth permanent magnetic devices, such as electroplating and magnetron sputtering, face issues like poor adhesion, insufficient anti-corrosion, high energy consumption, pollution, and inefficiency, which hinder mass production and ecological sustainability.
Innovation Solution
A vacuum composite plating equipment combining magnetron sputtering coating and multi-arc ion plating is used to form three layers of films on NdFeB rare earth permanent magnetic devices, enhancing anti-corrosion and magnetic performance while reducing the use of rare earth resources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electroplating or magnetron sputtering is used for surface treatment, then the process is simple, but the adhesion and anti-corrosion performance are insufficient
Solution Approach 1:
The patent combines magnetron sputtering and multi-arc ion plating into a composite plating process. The magnetron sputtering deposits the base coating layer, while the multi-arc ion plating enhances adhesion and anti-corrosion properties through ion bombardment and reactive plasma environment, creating a multi-layer structure with superior performance
Solution Approach 2:
The patent uses composite plating materials including aluminum, nickel, chromium, and rare earth elements in specific layer configurations. This composite material approach creates a multi-functional coating system that simultaneously provides adhesion, corrosion resistance, and magnetic field stability
2Reliability
If multi-arc ion plating is used to improve anti-corrosion, then anti-corrosion performance improves, but particle size is too large to meet requirements
Solution Approach 1:
The patent combines magnetron sputtering and multi-arc ion plating in a sequence where magnetron sputtering first deposits a fine-grained base layer with uniform composition, followed by multi-arc ion plating that enhances anti-corrosion through controlled ion bombardment. This combination allows the fine particles from sputtering to serve as a foundation while the ion plating adds protective functionality without creating large particles
3Productivity
If conventional electroplating is used, then the process is efficient, but energy consumption is high and pollution is generated
Solution Approach 1:
The patent uses vacuum plasma environment instead of conventional aqueous electroplating solutions. The plasma provides reactive species for coating deposition without requiring chemical baths, eliminating the need for water treatment and reducing chemical waste. The vacuum environment also prevents oxidation and contamination during the plating process
4Manufacturing precision
If magnetron sputtering is used for coating, then coating quality is good, but production efficiency is low for mass production
Solution Approach 1:
The patent integrates magnetron sputtering and multi-arc ion plating in a single vacuum chamber with sequential operation. The magnetron sputtering provides high-quality coating deposition, while the multi-arc ion plating stage enhances adhesion and anti-corrosion properties. This integrated approach maintains coating quality while improving overall process efficiency for mass production
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 method improves the anti-corrosion and magnetic properties of NdFeB rare earth permanent magnetic devices, making them suitable for high-demand applications like offshore wind power and hybrid electric vehicles, while conserving rare earth resources and minimizing environmental impact.
Implementation Method 1
a first layer is a first magnetron sputtering coated film
Implementation Method 2
a second layer is a composite plated film formed by magnetron sputtering coating and multi-arc ion plating
Implementation Method 3
A vacuum composite plating equipment combining magnetron sputtering coating and multi-arc ion plating is used
Data Source
AI summary
A method for manufacturing a NdFeB rare earth permanent magnetic device with composite plating includes steps of: firstly melting alloy, casting the alloy in a melted state onto a rotation copper roller with a water cooling function, so as to be cooled for forming alloy flakes; hydrogen decrepitating; mixing after hydrogen decrepitating; jet milling after mixing; mixing under nitrogen protection before molding in a nitrogen protection magnetic field pressing machine, and then packing in a protection tank before being moved out of the protection tank and isostatic pressing; sintering in a sintering device and aging for forming a NdFeB rare earth permanent magnet; machining for forming a NdFeB rare earth permanent magnetic device; and plating the NdFeB rare earth permanent magnetic device, wherein three layers of plated films are formed.