Projects

Barely a decade after the 2011 Rare Earth crisis, the world entered a second black swan event in the form of the Covid-19 pandemic. It fueled supply chain disruptions and threats of regional strangulation of critical materials o Europe and the Americas. Yet, the demand for NdFeB materials continues to surge with the growth of: high-efficiency motors, mobile consumer electronics, Electric Vehicles and clean energy solutions. Solutions to curb the dependence on both Light Rare Earths and Heavy Rare Earths, has primarily driven the advancement of NdFeB materials and their performance.

We review a variety of parallel technological strides in material advancements by Yunsheng to optimize performance, reduce dependence on LRE and HRE, and enable costdown in magnet cost. We will investigate the latest production-ready technologies being used. These technology solutions include: grain refinement, ternary Rare Earth material substitution, HRE-free and low-HRE materials, and Grain Boundary Diffusion (GBD) technologies.

Through the development of improved oxidation-resistant coating technology, Nichia has been able to create a SmFeN PPS resin-bonded magnet with the best long-term durability among rare-earth bonded magnets. Automotive applications, in particular, require PPS resin bonded magnets with superior reliability for long term usage. Nichia’s PPS SmFeN magnetic materials can achieve an irreversible flux loss of ≤3% in air at 150°C and aqueous solution at 120°C, making it suitable for harsh environment applications such as water pumps, oil pumps, and fuel pumps. Elevated conditions of greater than 300°C are required for PPS molding, during which magnetic powder can oxidize and degrade if not protected appropriately. Nichia will discuss the performance against currently used bonded Nd PPS materials through various comparisons.

As a proud sponsor of both the Belgian Formula Student and the Belgian Innoptus Solar electric race teams, Magcam has effectively employed its magnetic field camera technology and application expertise to enhance the performance of the permanent magnet rotors used in the electric motors in their respective electric race cars.

The Formula Electric car is powered by four radial-flux motors, whereas the Innoptus Solar car operates with an axial-flux motor. In both scenarios, we started the optimization process by measuring a large quantity of individual magnets using our magnetic field camera scanner. From the resulting magnetic field maps, detailed quality parameters were extracted, including overall magnet strength, magnetization angle error and localized magnetic homogeneity. By ranking these magnets based on the derived quality parameters, we were able to select the highest quality magnets for rotor assembly. This first crucial step assures that only qualified magnets are used. The assembled rotors were subsequently measured by Magcam's advanced radial/axial-flux rotor scanner.

This panel discussion will focus on both government and industry efforts to develop a robust North American supply chain of permanent magnets to support the energy sector industrial base (ESIB). Rare earth magnets, such as sintered neodymium-iron-boron (NdFeB) magnets, are especially important to the ESIB as they are critical components of traction motors in electric vehicles and direct drive generators in offshore wind turbines. Yet, nearly all supply chain stages of sintered NeFeB magnets are concentrated in China, posing a potential vulnerability for ESIB supply chains required to meet climate goals.

Moderator: Braeton J. Smith, Argonne National Laboratory

Panelists:
Helena Khazdozian, Advanced Manufacturing & Materials Technology Office, U.S. Department of Energy
Jacob Ward, Office of Manufacturing & Energy Supply Chains, U.S. Department of Energy
Alan Lund, MP Materials

We present here our newly discovered crystallographic site substituted high-performance hexaferrites to rare-earth cobalt to neo magnets applicable in vehicle, wind turbine, magnetic cooling, and other household technologies.

The research is supported by the Critical Materials Institute, an Energy Innovation Hub funded by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Technologies Office.

Battery-powered UAVs are revolutionizing today’s agriculture where they are used to spray fertilizers and more. These drones use motor drives that need to be lightweight and efficient to maximize working battery life and extend flight time between recharging. Wide-bandgap devices, and specifically Gallium Nitride (GaN) FETs, have demonstrated to improve BLDC motor drives in emobility and robotic applications. This paper will present the characteristics of GaN FETs that reduce weight and improve the motor drive system efficiency.

Join us in the exhibit hall for a happy hour reception. Enjoy complimentary refreshments and Hors d'oeuvres. Take this time network with the exhibitors and connect with fellow attendees via the 1:1 Meeting Program.

Since the fusion ignition breakthrough at the Lawrence Livermore Laboratory in late 2022,
billions of dollars have been funneled into achieving commercial fusion energy at scale and international
sprint has ensued to be the first company to achieve it. As a clean, limitless energy source, fusion could
solve the world’s energy problems and make today's climate change debate moot. Yet, to achieve
commercial fusion energy at scale, the world needs more of a critical component that is in short supply -
high temperature superconducting (HTS) magnetic wire. HTS magnetic tape is the only material that can
generate a strong enough magnetic field to achieve fusion energy in a device that is substantially smaller
than alternative technologies. This keynote talk will cover how the latest advancements in HTS magnets
are impacting the race for fusion energy and how one community aims to create an ecosystem to
support technological advancements in HTS magnets.

This presentation intends to delve into the subject of post-manufacturing degradation in the magnetic properties of stator cores. The analysis is based on evaluations carried out using Brockhaus measurement systems. Additionally, the presentation will explore the direct correlation between the deterioration in magnetic properties and the inferior performance of various types of electric motor topologies. This discussion can shed light on the importance of maintaining the quality of stator cores to ensure optimal electric motor performance.

ron Nitride permanent magnets have been recognized as a potential breakthrough for the industry. Based on the α”-Fe16N2 compound with high saturation magnetization (exceeding that of NdFeB) and a moderate magnetocrystalline anisotropy, the material pairs technical benefits – attractive magnetic performance and superior temperature stability to NdFeB – with the strategic benefit of being completely rare earth-free, relying instead on abundant commodity raw materials. Iron Nitride will act as an economical substitute for several grades of both sintered and bonded NdFeB magnets. Further, they offer significant advantages in terms of environmental footprint and recyclability.

Niron will address the background of the material, selections of the latest empirical data, implications for device design, and details on the process being taken with industry players to commercialize the first new permanent magnet in over 30 years.

For eMotor designers, seemingly small improvements in power and efficiency can have real-world tangible benefits like weight reduction, increased range, and cost savings. Optimizing the insulation materials in an eMotor is just one of the ways that can help design engineers reach their performance targets. Extruded KetaSpire® PEEK for magnet wire insulation and Ajedium PEEK slot liners have garnered significant attention in recent years as more sustainable and higher performing alternative insulation systems versus their incumbent counterparts, enameled wire and aramid papers.

In this presentation, we will show how the use of PEEK materials over traditional enamel magnet wire and aramid papers allows for reduced bill of materials across the electrified powertrain.

Abstract coming soon

Please check back soon for details in this presentation.

Please join us for a full buffet Lunch Reception. Keep the conversations going over a delicious lunch.

The presentation will comprise the development of two stray field immune magnet-sensor systems. It will cover the methods in their pre-design process as specific FEM simulations and 3D-Hall sensor measurement before realizing any hardware. Stray field immune sensors are often built by sensor pairs using the gradient principle. So, first stage tests including simulations and Hall measurements on different traces close the magnet and calculating potential sensor pair outputs are very valuable. Both can prove the viability of a devised systems and when successful the practical realization can be initiated. The whole way from pre-design investigations up to the hardware realization of a first sensor will be sketched in the presentation.

This presentation commences with an introduction to Litz wire by Mr. Benjamin Braggins. He will explore various types of Litz wire, discuss VDE and UL certifications, cover coating options such as serving and taping, and provide valuable insights into the best design practices for electric motors and magnetic components. Mr. Rajasekhara will continue highlighting the main obstacles in winding and welding processes that involve litz wire and how they can be overcome. From how to control tension to get perfect layering despite the variable morphology of the wire, how to avoid wire untwisting, up to how to get clean and solid wire/terminal welding points with wire with high thermal class and composed of many tiny, twisted wires.

Join your colleagues in the Exhibit Hall for a short networking break and grab a snack. Take this time to also schedule 1:1 Meetings with exhibitors, speakers and attendees.

Join your colleagues in the Exhibit Hall for a short networking break and grab a snack. Take this time to also schedule 1:1 Meetings with exhibitors, speakers and attendees.

Join us in the Networking Lounge for a break with drinks and snacks. Take this time to connect with some of the industry leading suppliers and solution providers.

Global demand for electric vehicles is booming, with 2023 sales expected to grow 35% after a record-breaking 2022. This explosive growth has led to electric vehicles moving from a 4% share of the overall care market to a 14% share in 2022. Three markets are dominating the EV industry – China, Europe, and the US. China is the frontrunner, manufacturing more than half of all electric vehicles. However, the U.S. is ramping up EV production and by investing more than $90 billion in EV manufacturing. Permanent magnet motors are by far the most commonly used electric motor in the EV market thanks to their high-power density, torque density, and efficiency.

Moderator: Jeff Whalen, Founder & Director, MagCorp

Panelists:
Chris Rainone, Global Supply Chain SME for Critical Materials & Supply Chain, Lockheed Martin
David Miller, President, Magnetic Instrumentation