NdFeB Magnet Composition Without Heavy Rare Earths
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Solution Overview
Problem
Existing neodymium-iron-boron magnet materials struggle to significantly improve coercivity and remanence without relying on large amounts of heavy rare earth elements, and partial replacement with praseodymium offers limited performance enhancement.
Innovation Solution
A neodymium-iron-boron magnet material composition comprising specific mass percentages of Pr, Nd, Al, B, Fe, and optionally heavy rare earth elements like Dy and Tb, along with optional additives such as Cu, Zr, Ga, and Co, prepared through melting, hydrogen decrepitation, sintering, and aging, enhances performance without heavy rare earth elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If neodymium is replaced with praseodymium partially in the magnet material, then the cost is reduced, but the coercivity and remanence cannot be significantly improved
Solution Approach 1:
The patent changes the compositional parameters by specifying precise ranges of Pr (17.15-30%), Nd (1.5-14%), and Al (0.5-3%) to achieve optimal magnetic properties. By adjusting these parameters within defined ranges, the invention achieves high coercivity and remanence without relying on heavy rare earth elements, thus reducing cost while maintaining performance.
Solution Approach 2:
The patent creates a composite rare earth composition combining Pr, Nd, and Al in specific proportions. This composite approach leverages the synergistic effects of different elements: Pr provides cost reduction and adequate magnetic properties, Nd enhances coercivity, and Al improves remanence, achieving superior overall performance without heavy rare earth additives.
2Reliability
If heavy rare earth elements are added to improve magnet material performance, then coercivity and remanence are enhanced, but the cost increases significantly
Solution Approach 1:
The patent extracts and eliminates heavy rare earth elements (Dy, Tb, Ho) from the magnet material composition. By removing these expensive components and replacing them with a optimized combination of Pr, Nd, and Al, the invention achieves comparable or superior magnetic properties at significantly lower cost.
Solution Approach 2:
The patent substitutes expensive heavy rare earth elements with cheaper alternative elements (Pr, Nd, Al). This replacement strategy uses more abundant, lower-cost materials to achieve the same functional performance, making the magnet material economically viable for large-scale applications.
3Reliability
If large amounts of heavy rare earth elements are added to achieve excellent magnet material performance, then coercivity and remanence are significantly improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by concentrating the functional benefits in specific elements within the composition. Rather than distributing functionality across multiple heavy rare earth elements, the invention focuses on optimizing the local contribution of Pr, Nd, and Al in specific proportions, simplifying the overall manufacturing process while maintaining excellent magnetic properties.
Data Source
AI summary
Disclosed are a neodymium-iron-boron magnet material, a raw material composition, a preparation method therefor and a use thereof. The raw material composition of the neodymium-iron-boron magnet material comprises the following components by mass percentage: 29.5-32.8% of R′, wherein R′ includes Pr and Nd, and Pr≥17.15%; Al≥0.5%; 0.90-1.2% of B; and 60-68% of Fe. The percentages are the mass percentages relative to the total mass of the raw material composition of the neodymium-iron-boron magnet material. Without adding a heavy rare earth element to the neodymium-iron-boron magnet material, the performance of the neodymium-iron-boron magnet material can still be significantly improved.