Next-generation RE magnets look for material alternatives

NdFeB magnets remain the most powerful type of permanent magnets in the market. Based on rare-earth elements (REE), they exhibit a high energy product and coercive force. Introduced in the early 1980s, these magnets have since been optimized to meet performance and cost requirements for a range of different applications.

However, the supply of REEs needed for production poses a risk, having been disrupted once before, between 2010 and 2011, and being threatened by the US-China trade war. Even under optimal circumstances, these materials are not easy to obtain, involving complex extraction and processing methods with significant impact on the environment.

To address these issues, producers have been researching substitute materials and other REEs that can be more easily sourced. The end-goal is to reserve precious rare earths for applications that really need them, which include electric (EVs) and hybrid vehicles (HEVs), and wind turbines, or avoid them altogether.

Rare-earth iron-nitrides (REFeN) and rare-earth iron-carbides (REFeC) are some of the potential alternatives currently under development. These are considered fourth-generation rare-earth magnets after SmCo5, Sm2Co17 and NdFeB. REFeN magnets have higher Curie temperature, lower temperature coefficient and better corrosion resistance than their NdFeB counterparts.

World's biggest source

China is the largest producer not only of NdFeB magnets but also of REEs. It generates nearly 90 percent of global output for the latter, according to the China Rare Earth Industry Association.

Between 2010 and 2019, the country's NIB magnet production posted a 9.06 percent CAGR. It reached 180,300 tons in 2019 from 164,500 tons the previous year. Of this, 170,000 tons were sintered units and 7,900 tons were bonded types, respectively increasing 9.7 and 5 percent over 2018 figures.

In the high-performance subcategory, covering magnets with total value of intrinsic coercivity and energy product exceeding 60, China accounted for 23,000 tons of the world's 48,000-ton output or 47.92 percent in 2018 and pushed past 50 percent the following year.

China will continue to consolidate its global position to take advantage of demand from EVs, industrial robotics and high-speed railways, which is projected to rise by more than 20 percent annually.

In 2019, NdFeB magnets were shipped to over 100 countries, according to China Customs. Germany, the US and Japan were the top destinations, with respective shares of 17.6, 11.3 and 11.1 percent.

In 2020, China's overall output for the category was stable despite the pandemic, and is expected to rise, along with export shipments, in 2021 and onward.

Sintered, bonded & hot-pressed

Chinese companies offer sintered, bonded and hot-pressed NdFeB magnets for consumer electronics, household appliances, and the automotive, industrial and renewable energy sectors.

Production of sintered magnets reached 17,000 tons in China in 2019, representing 94.3 percent of the country's total volume in the NdFeB category based on information from the industry association. Bonded variants made up 4.4 percent and hot-pressed units 1.3 percent.

Bonded magnets are targeted for office automation applications, A/V equipment, micromotors, and various devices and instruments. Hot-pressed types are mainly for motors used in passenger cars' electric power steering systems.

In the coming years, sintered magnets will continue to dominate supply. These are mainly used in conventional gasoline and electric vehicles, and industrial fields, collectively accounting for 37.5 percent of shipments, according to the China Rare Earth Industry Association. Other key applications are the power-generation industry with an 11.8 percent share and consumer electronics at 10.9 percent.

Sintered NdFeB magnets from Chinese manufacturers are available in grades of N35 to N52, 35M to 50M, 30H to 48H, 30SH to 45SH, 28UH to 35UH and 28EH to 35EH. Jyun Magnetism Group Ltd can offer N55 magnets.

The bonded subcategory includes BNP6 to BNP12L and BNI3 to BNI5SR variants.

Mainstream options are ring, disc, cylindrical, arc, block, stick, bar and cube variants with nickel, NiCuNi, zinc, gold, silver, chemical or PTFE coating to protect against corrosion.

Other specifications are widely accepted.

Suppliers will continue to improve product performance, and aim for higher-grade releases.

Companies source rare-earth materials mainly from Baotou and Ganzhou. Other inputs, such as copper and nickel, also come from domestic sources. Material costs rose slightly in the past six months, according to manufacturers interviewed by Global Sources Electronic Components. In the months ahead, these are projected to become stable and keep product prices from fluctuating.

300-strong production pool

More than 90 percent of 300 NdFeB suppliers in China are domestically owned, and also offer magnetic materials.

Fewer than 50 companies operate on a large scale, with annual output exceeding 10,000 tons. These include Zhong Ke San Huan, Ningbo Yunsheng, Zhenghai Magnetic, Xiamen Tungsten and Innuovo Magnet.

Ningbo in Zhejiang province is the largest manufacturing base in the country, gathering about 100 suppliers. Ningbo Yunsheng, Newland Magnet and Ningbo Permanent Magnetic are some of the key companies. The city accounts for over two-thirds of China's total output.

N50 NdFeB magnet

In N50 grade, Jyun Magnetism Group Ltd's Strong Magnet-3 has zinc, nickel or epoxy plating for improved corrosion resistance.

The order quantity is negotiable. Delivery lead time is 15 days.

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NdFeB with ±0.05mm size tolerance

This Neodymium Magnet 1022-06-9839 from Ningbo Hui Hesing Advanced-Tech Material Co. Ltd comes in disc, cylinder, block, ring, countersunk, segmented, trapezoid and irregular shapes. Size tolerance is ±0.05mm. Available grades include N35 to N52, N35M to N50M, N35H to N48H, N35SH to N45SH, N30UH to N40UH and N30EH to N38EH.

The minimum order of 500 units has an eight-day delivery lead time.

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Sintered NdFeB magnet in various grades

From Ningbo Lihe Magnetic Industry Co. Ltd, this LM20201217 sintered NdFeB magnet comes in N35, N38, N45 and N52 disc-shaped variants. The anti-corrosion surface treatment options for this RoHS-compliant unitinclude double-nickel, NiCu, zinc, copper, silver, PTFE, parylene and Everlube.

The 100-unit minimum order is delivered within 10 days.

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53 to 55MGOe NdFeB Magnet

Ningbo Yuansheng Magnet Co. Lt's 54M-grade NdFeB Magnet has 14,200 to 14,800 Gauss remanence, more than 14,000Oe intrinsic coercivity, 53 to 55MGOe maximum energy product and 100 C maximum operating temperature.

The supplier requires a minimum order of one carton. Delivery lead time is seven days.

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