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New Processing Technology for Permanent Magnets

Electron Energy Corporation (EEC)
Solid State Processing of Fully Dense Anisotropic Nanocomposite Magnets
Program: 
ARPA-E Award: 
$2,903,999
Location: 
Landisville, PA
Project Term: 
04/15/2013 to 02/14/2017
Project Status: 
ALUMNI
Technical Categories: 
Critical Need: 
Rare earths are naturally occurring minerals with unique magnetic properties that are used in electric vehicle (EV) motors and wind generators. Because these minerals are expensive and in limited supply, alternative technologies must be developed to replace rare-earth-based magnets in motors and generators. Alternatives to rare earths will contribute to the cost-effectiveness of EVs and wind generators, facilitating their widespread use and drastically reducing the amount of greenhouse gases released into the atmosphere.
Project Innovation + Advantages: 
EEC and its team are developing a new processing technology that could transform how permanent magnets found in today's EV motors and renewable power generators are fabricated. This new process, known as friction consolidation extrusion (FC&E), could produce stronger magnets at a lower cost and with reduced rare earth mineral content. The advantage of FC&E over today's best fabrication processes is that it can be applied to unconsolidated powders as opposed to solid alloys, which can allow magnets to be compacted from much smaller grains of two different types, a process which could double its magnetic energy density. EEC's process could reduce the need for rare earth mineral in permanent magnets by as much 30%.
Potential Impact: 
If successful, EEC's new process would support the growing market of renewable power generators and EV motors with alternative higher-performance magnets compared to the imported rare earth magnets currently used in these machines.
Security: 
The U.S. produces a small fraction, globally, of industrial rare earths. Developing alternatives to the use of rare earths has the potential to reduce our dependence on these materials and will have a positive impact on our national economic and energy security.
Environment: 
The transportation and electric power sectors account for nearly 75% of U.S. greenhouse gas emissions each year. Cheaper motors will encourage the widespread use of EVs and wind power, significantly reducing emissions.
Economy: 
The U.S. spends nearly $1 billion per day on imported petroleum. Improvements in motor technology will encourage broader use of EVs, reducing the economic impacts of oil price fluctuations.
Contacts
ARPA-E Program Director: 
Dr. Ji-Cheng Zhao
Project Contact: 
Dr. Jinfang Liu
Partners
Ames National Laboratory
Pacific Northwest National Laboratory
Release Date: 
11/28/2012