0

10

20

30

40

50

60

0

80

160

240

320

400

480

Maximum Energy Products (MGOe)

Maximum Energy Products (kJ/m)

3

Guiding principles which led to the new magnets:

Transition

Old New

Guiding principle

Alnico SmCo5Getting high coercivity by using high anisotropy fields originated from 4f electrons

SmCo5 Sm2Co17Getting high remanence by using high saturation magnetization of Sm2Co17

Sm2Co17 Nd2Fe14BGetting an Fe-base magnet by extending the search for R-Fe-X ternary systems with various R

(R=Rare Earth)

At MMM Conference, November 10, 1983

MRI, Speaker

HEV driving motor

�-50

X�NEOMAXNNEOREC

Compressor motor

Motor for robotics

Generator

HDD, CD, DVD, MD, VTR, Digital camera, Head phone

ABS sensor

OA�FA motor

Servo motor

�-46BH

�-49H

�-40BH

�-39SH

�-38AH

�-35SH�-35EH

�-32EH

�-48

30

40

45

50

35

10 20 30

HcJ�kOe�

�BH)max�MGOe�

Map of the magnetic properties of the NdFeB sinteredmagnets and corresponding applications

MRI, Speaker

HEV driving motor

�-50

Compressor motor

Motor for robotics

Generator

HDD, CD, DVD, MD, VTR, Digital camera, Head phone

ABS sensor

OA�FA motor

Servo motor

�-46BH

�-44H

�-42VH

�-39SH

�-38VH

�-35SH�-35EH

�-32EH

�-48BH

2000�

30

40

45

50

35

10 20 30

HcJ�kOe�

�BH)max�MGOe�

Map of the magnetic properties of the NdFeB sinteredmagnets and corresponding applications

�1987

Raw Materials Melting Course

GrindingJet

Milling Compaction Sintering Annealing

Nd, Dy, Fe, B

Process for the NdFeB sintered magnets

High magneticfield

Raw Materials Melting Course

GrindingJet

Milling Compaction Sintering Annealing

Nd, Dy, Fe, B

Process for the NdFeB sintered magnets

Improvements: StripCasting

HydrogenDecrepitation

Lubricant

Binder

Low pressurepressing

Low oxygenprocess

NdFeB Sintered Magnets

Amount of Production(t/year)

Amount of Production(t/year) NdFeB Bonded Magnets

MRI, Speaker

HEV driving motor

�-50

X�NEOMAXNNEOREC

Compressor motor

Motor for robotics

Generator

HDD, CD, DVD, MD, VTR, Digital camera, Head phone

ABS sensor

OA�FA motor

Servo motor

�-46BH

�-44H

�-42VH

�-39SH

�-38VH

�-35SH�-35EH

�-32EH

�-48BH

30

40

45

50

35

10 20 30

HcJ�kOe�

�BH)max�MGOe�

Map of the magnetic properties of the NdFeB sinteredmagnets and corresponding applications

VCM

Application of NdFeB sintered magnets(Pick-up for CD-ROM)

Tracking coil

Focus coil

NdFeB magnetLense

Optical pick-up

Inside the houseOutside the house

Compressor

IPM rotor

NdFeB magnet

DC motor

Application of NdFeB sintered magnet(IPM compressor motor for air conditioner)

Air Conditioner

Induction motor IPM synchronous motor

Efficiency is improved by 20% statistically !

35km/liter !

MRI, Speaker

HEV driving motor

�-50

X�NEOMAXNNEOREC

Compressor motor

Motor for robotics

Generator

HDD, CD, DVD, MD, VTR, Digital camera, Head phone

ABS sensor

OA�FA motor

Servo motor

�-46BH

�-44H

�-42VH

�-39SH

�-38VH

�-35SH�-35EH

�-32EH

�-48BH

10 20 30

HcJ�kOe�

30

40

45

50

35�BH)max�MGOe�

Map of the magnetic properties of the NdFeB sinteredmagnets and corresponding applications

Strong needs

21Nd-10Dy-68Fe-1B

31Nd-68Fe-1B

26Nd-5Dy-68Fe-1B

30

40

45

50

35

10 20 30

Nd

Dy�0.1

Nature

Composition of the NdFeB sintered magnets�BH)max�MGOe�

HcJ�kOe�

MRI, Speaker

HEV driving motor

�-50

X�NEOMAXNNEOREC

Compressor motor

Motor for robotics

Generator

HDD, CD, DVD, MD, VTR, Digital camera, Head phone

ABS sensor

OA�FA motor

Servo motor

�-46BH

�-44H

�-42VH

�-39SH

�-38VH

�-35SH�-35EH

�-32EH

�-48BH

30

40

45

50

35

10 20 30

HcJ�kOe�

�BH)max�MGOe�

Map of the magnetic properties of the NdFeB sinteredmagnets and corresponding applications

Hybrid car applicationrequires this range !

�BH)max�MGOe�

30

40

45

50

35

10 20 30

HcJ�kOe�

0% Dy

Direction of our development

Increasing anisotropy

Sintering

PresslessProcess (PLP)

PLP

Coercivity of NdFeB sintered magnets (PLP Experimental data)

5μm�13.5kOe

2.9μm�16.5kOe

2.7μm�17kOe

1 32 54 76 10984.53 7.56.0 9.0 15.012.01.5

D�1.5d

25

20

15

10

Particle size d�μm�

H cJ�kOe�

Grain size D�μm�

�BH)max�MGOe�

30

40

45

50

35

10 20 30

HcJ�kOe�

0% Dy

PLP Record

(Particle size=2.7μm�

2005 2006 2007

��/kg�Prices of Rare Earths

Nd price also soars !

��/kg�Prices of Rare Earths

Our goal for PLP

Net Shape Production

Yield �90�

New National Project in Japan

Subject: “Development of Alternative Materials

for Rare Metals”

Rare Metals: � W for toolings� Dyfor NdFeB magnets�In for LCD

Term: 2007�2011Budget: 5.5BJPY (�34M€�Members for �Dy: �Intermetallics Co., Ltd.

�Tohoku University�National Institute for

Material Science etc.

Coercivity of NdFeB sintered magnets (PLP Experimental data)

5μm�13.5kOe

2.9μm�16.5kOe

2.7μm�17kOe

25

1 32 54 76 10984.53 7.56.0 9.0 15.012.01.5

D �1.5d

20

15

10

Particle size d�μm�

H cJ�kOe�

Grain size D�μm�

�BH)max�MGOe�

30

40

45

50

35

10 20 30

HcJ�kOe�

0% Dy

Object of the National Project

Present level

How to reach the object ?

�A thorough investigation about the relation between microstructure and coercivity in NdFeBmagnets.

�A thorough investigation about the mechanism of the magnetization reversal, including calculations based on the first principle.

�Determination of the ideal structure for the NdFeBmagnet.

�Determination of the process for the NdFeBmagnet with the ideal structure.

“NdFeB Magnets rescue the Earth.”

�All motors in all factories →NdFeB PM motors

�All motors for elevators →NdFeB PM motors

�All motors for air conditioners →NdFeB PM motors

�All motors for refrigerators →NdFeB PM motors

�All motors for trains →NdFeB PM motors

To rescue the Earth, let’s act:

�All cars →HEV or EV

Problems ? Let’s overcome !

�Shortage of Nd, Dy ? →Find new mines !

�Cost of NdFeB magnets ? →Find a way for cost

reduction !

�Cost of HEV → Develop HEV with acceptable cost !

(Toyota is doing.)

����

����

e. g.

Is it impossible to find a new magnet

after the NdFeB magnet ?

To find a new magnet after the NdFeB magnet, a

new guiding principle must be found:

The guiding principle for the NdFeB magnet is

useless any more.

We have all sorts of mystery in the coercivity of the NdFeB magnets.

Profound and thorough researches on the coercivity of the NdFeB magnets will give us a new guiding principle for a new magnet !