THERMALLY STABLE, CLADDED PERMANENT MAGNETS, AND COMPOSITIONS AND METHODS FOR MAKING THE SAME

• Main Authors: YAHATA, Brennan, GROSS, Adam, LAPLANT, Darby, HENRY, Christopher, NGUYEN, Raymond, KIM, Christine, SUCICH, Amber
• Format: Patent
• Language: English
• Published: 07.09.2023
• Subjects: BASIC ELECTRIC ELEMENTS; ELECTRICITY; INDUCTANCES; MAGNETS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES; TRANSFORMERS

The disclosed technology provides a nanofunctionalized magnetic material feedstock comprising: from 50 wt % to 99.5 wt % of magnetic microparticles having an average microparticle effective diameter from 1 micron to 500 microns; from 0.4 wt % to 40 wt % of one or more rare earth elements; and from 0.1 wt % to 10 wt % of metal-containing inoculant nanoparticles, wherein at least 1 wt % of the inoculant nanoparticles are chemically and/or physically disposed on surfaces of the magnetic microparticles. The nanofunctionalized magnetic material feedstock is processed using high-throughput laser-based additive manufacturing to optimize the architecture of NdFeB or other magnets, generating site-specific, demagnetization-resistant microstructures. This disclosure teaches a rapid, single-step laser-based process to tailor the easy axis alignment, grain size, and microstructure of a permanent magnet at corners and edges to resist demagnetization.