How Neo Magnets are made

1. Get ready Materials for the Reaction

The essential compound for most Neodymium magnets is Nd2fe14b. In practice, the real compound response utilized might be more muddled. A regularly utilized response is:

57 Fe + 8 B + 10 Fe2o3 + 7.5 Nd2o3 + 52.5 Ca -> Nd15fe77b8 + 52.5 Cao

Vacuum Induction Furnace

Note that the powder framed by this response is somewhat unique in relation to the Nd2fe14b proportion. Magnets are regularly made both Nd-rich and B-rich, where completed magnets commonly hold non-attractive bits of Nd and B in the grain, inside which are exceptionally attractive Nd2fe14b grains.

For higher temperature magnet reviews, extra components are included. At the point when little measures of Iron (Fe) are supplanted with Cobalt (Co), the properties enhance at hoisted temperatures, yet the natural coercivity diminishes. In the event that little divides of Neodymium (Nd) are supplanted with Dysprosium (Dy), the inherent coercivity is enhanced; however the greatest vitality item (Bhmax, a great measure of a magnet's quality) diminishes. It is regular to utilize both Co and Dy together.

2. Dissolving

The concoction response portrayed above happens in a vacuum affectation heater. The items are warmed by making electrical swirl momentums through it, all in a vacuum to keep contaminants out of the response.

3. Processing

Plane processing transforms the ensuing material into a powder with a little molecule size. The normal molecule size is on the request of 3 micrometers.

4. Pressing

Pressing Steps

The powder is pressed together to structure a strong that has a favored charge bearing. In a system known as kick the bucket annoying, the powder is pressed with a bite the dust into a strong at hoisted temperatures of something like 725°c. The robust is then set in a second bite the dust, where it is compacted to a more extensive shape that is about a large portion of its unique stature. This adjusts the favored course of polarization parallel to the pressing bearing. For a few shapes, there are routines that incorporate an apparatus that produces an attractive field amid pressing to adjust the particles.

5. Sintering

Sintering is a typical process in powder metallurgy. The material is layered at lifted temperatures (as high as 1080°c) underneath the material's liquefying point, until its particles stick to one another.

6. Machining

The sintered magnets are sliced to the coveted shape utilizing a pounding methodology. Less regularly, complex shapes are made with electric release machining (EDM). Due to the high material expense, material misfortunes because of machining are kept to a base. No successful method for reusing the waste has been produced.

7. Plating

The individual magnets are electroplated with three layers: nickel, copper and nickel. This is essential on the grounds that un-plated neodymium magnets are exceedingly inclined to consumption, and will rapidly lose their attractive properties in the vicinity of dampness.

8. Charge

Right now, the magnets have a "favored" bearing of polarization, however they are not polarized. They are put in an apparatus that will open the magnet to an exceptionally solid attractive field for a short minute. It's essentially a huge curl of wire encompassing the magnet(s). The charging supplies utilization banks of capacitors and a truly immense voltage to get such a solid present for a concise moment.

9. Examination

The nature of the ensuing magnets is examined for an assortment of properties. A computerized measuring projector checks the measurements. A covering thickness estimation framework utilizing x-beam fluorescence engineering confirms the thickness of the plating. Intermittent testing in salt-spread and weight cooker tests additionally confirm the execution of coatings. A hysteresigraph measures the BH Curve of magnets, which affirms that they are completely charged obviously for the magnet's evaluation.

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Cutting edge neodymium magnet incorporated wind turbines

Massive surge in the utilization of neodymium magnets by today’s developed era has resulted in an enormous increase in the demand of this spectacular product. The global demand for wind turbines is on a continuous rise owing to its ability of providing a great deal cleaner, cheaper and a much more efficient source of electric energy. Wind turbines basically work by converting wind energy in to electric energy which is then utilized both industrially as well as domestically on a large scale. Despite its simplistic basic structure, Wind turbines are extremely complex machines which when operate at full throttle have managed to meet the endless low-cost energy demands of today’s population.  This article would focus on how neodymium magnets play their part in improving the efficiency, reliability and the overall results of wind turbines in their efforts to greenify electricity production worldwide.

Neodymium when combined with Iron, Boron and other elements results in the production of the world’s strongest magnets. Modern day wind turbines rely largely on the principles of electromagnetism. Such that the strength of neodymium magnet within a wind mill is directly proportional to the amount of energy produced within a set time period. In previous years, traditional commercial level wind turbines were being used wherein an induction generator was used in order to convert mechanical energy to electrical. In the absence of permanent magnets, such turbines operated at a low rotor speed of 10-20RPM and were much more prone to mechanical faults and consequently higher maintenance costs. As wind turbines evolved, introduction of neodymium permanent magnet blocks within the electromechanical system enabled the production of more reliable wind turbines. With a decrease in maintenance costs, the turbines non producing time decreased considerably as well. Another advantage of the cutting edge neodymium incorporated modern wind mills is that they give much greater efficiencies even at low wind speeds. Both arc and block shaped permanent neo magnets are most commonly used in wind turbines.

Statistics show that wind energy is the most cost-effective source of carbon reduction as well as simultaneously provides large quantities of energy at whole sale competitive prices. With this awareness came a direct jump in the amount of rare earth elements demanded especially neodymium. The annual Hong Kong conference calculated that under stable pricing, the global demand of neodymium element has risen from 4500 tons in 2012 up to 8000 tons in 2014. Therefore, despite being available in abundant quantities, neodymium magnets are now a precious yet rapidly depleting product due to its wide scale application in various aspects of life.

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Neodymium iron boron magnets and Assemblies

The Neodymium iron boron magnets, is otherwise known in different names like neodymium magnets, Nd2Fe14B magnets, neo magnets and Nd-Fe-B magnets. The metal is first introduced in the late of 1980s. Neodymium Magnet has a tetragonal crystal structure. It is a type of permanent magnet. Neodymium has strong magnetic field and sue to its strength it can be used in various industrial, commercial, medical and household purposes. However it is very widely used in the field of technology. A heavy rare earth component called Dysprosium is often mixed to the reaction to produce a powerful Neodymium Magnet with enhanced intrinsic coercivity as well as maximum operating temperature. Other element is also added so as to manufacture different kinds of Neodymium Magnet useful of many other purposes.

The basic advantages that Neodymium Magnet is that it can produce high-end maximum energy magnetic product due to its strong magnetic field. The other advantage is it is not very expensive material. Neodymium Magnets are not the rare material. Its supply is not at all restricted as well. So you can see Neo Magnets widely used in the many modern applications like servomotors, spindle and stepper motors, compressor motors,  electric generators for wind turbines, rive motors for hybrid and electric vehicles, actuators, loudspeakers, magnetic bearings, computer hard disk drives, sensors, magnetic resonance imaging (MRI), flow meter and medical devices.

Apart from the Neodymium Magnets there are the Magnet Assemblies which are high-performing in the field of technology. These Magnet Assemblies help to amplify signals at microwave frequencies through the use of klystrons, Traveling wave tubes and magnetrons. It is helpful in generating microwave frequencies which is effective for communications as well as electronic countermeasure systems.

Another Magnet Assemblies is the generators and motors. The features like low weight, ultra-high temperature tolerance power as well as outstanding reliability made Neodymium Magnets ideal for the application of generators, motors and actuators. Beside that it is also used widely in military, commercial as well as aerospace applications.

Moreover, due to advancement of technology now the Magnet Assemblies enables us to improve magnetic performance through improving interior magnet structure, which brings lots of improved benefits in the form of compact size, weight, power density, and cooling, as compared to the old traditional machines. The new technique makes the overall size and weight of the motor to be reduced with better model design and look.

The neo magnetic product also produce magnetic assemblies intended for the inertial guidance systems which can be widely used in marine vessels, aircraft, spacecraft navigation as well as control systems.

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A study on the best material for shielding a magnet

Magnets have the magnetic field otherwise called as pull force, due to which it attracts the things towards it. But often it come across the issue that we mounted magnet for a specific reason but the strong magnetic field cause affect on other electronic material. Then what is the solution for it, here you wander to shield a magnet. But are you sure that  a magnetic field of a Neodymium Magnet can be blocked at one side so that it will only pulls on other side.

So the First and foremost thing is that be sure Magnetic shielding does not in any way block a Neo Magnet’s magnetic field. There is no such material on the earth which can stop the effect of magnetic field traveling from right the Neodymium North Pole to its South Pole.

The main reason for the need of magnetic shielding is that almost all the magnetic fields are manmade, which are there in Neodymium Bar Magnets, solenoids, and some motors and transformers. These Neodymium Magnets are used in creative applications to create sound in the mechanism of speakers, record resonance images by MRI technology. But often the field interferes with some other sensitive electronic equipment, which need shielding.

Any ferromagnetic material, which consists of iron, nickel or cobalt, can work effectively for shielding Neo Magnet. As you know most steels are ferromagnetic metal. So, steel can work effectively for a redirecting shield. Another advantage of using steel as a shielding material is that it is cheap and easily available.

The next concern is what should be the thickness of the shield matters. This will definitely depend on the size and nature of the magnetic force of the Neo Magnet you are shielding. The shield material thickness should be remarkable. It should be up to a certain point to hold all more lines of flux. Thus it should be thick enough to hold the maximum flux possible.

It is advisable to pick a material for shielding depending on your particular shielding problem. MuMetal is the best shielding material for low field strength of sensitive electronics devices. For other applications involving large powerful Neodymium magnets, steel is considered as the best solution for Magnetic shielding.

It has been seen that in lower flux density fields, materials of high permeability offer a higher attenuation, while in higher Neo Magnet field densities, the MuMetal becomes saturated, often loses its capability. In a circumstance like this, steel can be proved as a good attenuation having a much higher saturation threshold.

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Claims of Neodymium magnet

Neodymium magnet is a rare earth permanent magnet material, which is a mixed metal and can be used to create influential magnets applicable in various industrial and other uses. Among all other type of magnets available on the earth the Neodymium magnets are proven the ultimate strongest magnet known relative to their mass. That means a small piece of Neodymium magnet have the ability to support millions of times its own weight. However Neodymium magnet is not at all rare in nature. It is abundance in supply. You can get easily Neodymium magnet in the open market or can shop online as well. It is the strongest magnet. Due to its strength and powerful magnetic field it is used in wide range of applications, such as in the area like jewelry, toys and computer equipment.

Neodymium magnet is versatile in their application just because it is strong enough. Both the commercial as well as the industrial segment make use of the material. Neodymium magnet is used by the jewelry to keep the earring in a particular place without going here and there. Neo magnet is also useful for some very serious affairs like in making the equipment for air craft and all. Moreover neodymium magnets are being sent into space for bringing the dust and particles from the surface of Mars. The dynamic capabilities of Neo magnet have directed them to be used in experimental levitation devices. Further the material is very commonly used in the tasks like oil filters, welding clamps, costumes, mounting tools and many more.

Apart from the industrial application and commercial use of Neodymium magnet, it has some other uses for home and office purposes. These are useful in locating the metal studs in the wall of the house very quickly only through running a piece of magnet slowly over the wall to feel the pull force. It also do Seal off air-conditioning vents to develop home heating through placing vinyl-coated sheets. It is also use to hang and stick different documents and to demonstrate important piece of information. Neodymium magnet can collect the spilled nails and pins from the surface without any effort.  It can help you to pin blueprints of a construction site onto the side of the truck. Neo magnet helps in cleaning the construction site. It can easily clean up metal shavings onto the workshop floor that have fallen from the bench grinder.

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Factors Which Can cause to Demagnetization

A commercially viable magnet such as Neodymium magnets can hold their magnetic field for more than thousands of years, if no external demagnetize field will influences its force. There may be a chance of slight degradation due to efflux of time or due to the aging process of the material. But truly speaking it can hold an effective magnetic field for the years long. Often it has been seen that magnets used in the real world application has a chance to loss its magnetic field as always exposed to external demagnetizing conditions. Magnet which is partially demagnetized cannot perform well in specific area of application.

Different Neodymium magnets are powered with different level of external magnetic field.  They cannot perform beyond that level. If at any time you want to change the magnetic field of the material you need to expose them to an external energy of higher magnetic field type of material. However, the following are some real world factors which adversely affect the strength and stability of Neodymium magnets.

TIME

Due to the aging process or wear and tear during the life span of the Neodymium magnets, it has been seen that the material can decrease 3percent of their value.

TEMPERATURE

Magnets highly affected by the temperature factor, which can result in three kinds of losses such as:

REVERSIBLE LOSSES: These are the losses which may occur during the heating process but the magnet can recover the strength back which the process is over. It varies with different grades of material.

IRREVERSIBLE LOSSES: These are the losses which are permanent in nature. It is the damage due to fluctuation in the temperature of heating. It generally takes place when the operating point cascade below the material demagnetization curve.  The mechanical process of external re-magnetization can help the magnet to recover the magnetic field back.

METALLURGICAL CHANGES: It is the consequences when the permanent magnets are exposed to very high temperatures.  Metallurgical changes make the Neodymium magnets useless to be used in any application.  That is the reason why the manufacturers have set the Maximum Use Temperatures for all the grade of Neodymium magnets.

RELUCTANCE CHANGES

As per the material experts the removal and replacement of magnetized Neodymium magnets may results in operating slope to fall. When this operating slope drops down the magnetic field also decline and the magnet cannot perform with the previous strength. Thus any change or alteration in the magnet circuit during use may cause reluctance changes.

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The contest to build the world's strongest magnet

Like all other material, magnets also have to go through some stages which are focused below. This really describes the production process neodymium magnets, intended for practical magnet users.

1. Proper combination of raw elements:

The fundamental compound used for manufacturing Neodymium magnets is Nd₂Fe₁₄B.  However the practical use differs from this. The proportion of the compounds like Iron, Cobalt, Neodymium and Neodymium are altered in order to get different types of Neodymium magnets suitable for different purposes. The element iron increases the coercivity of magnets, while adding more amount of Cobalt can improve the properties at elevated temperatures. Neodymium can result in an improved intrinsic coercivity, however Dysprosium can affect the strength of the Neo Magnets.  So a required composition is used depending on the application.

2. Melting

In this phase the chemical reaction will be heated in a vacuum to keep it away from contamination. A vacuum induction furnace is used in this process.

3. Milling

After going through jet milling process the material become a power having the small particles of about the size of 3 micrometers.

4. Pressing

In this step the powder is pressed with a die at elevated temperatures of nearly 725°C. Then it is compressed into another die, about half of its original height. Here the atoms align at parallel to the pressing direction which increases magnetization strength in the material.

5. Sintering

Through the process of sintering the powder metallurgy is compressed at elevated temperatures just below the melting point of the material. Here the particles of the material adhere to each other.

6. Machining

Using the process of grinding the sintered magnets can be cut into the preferred shape suitable for different application. The only drawback of the process is high material cost due to wastage of material in the process.  The wasted material of the process cannot be used for recycling purposes even. That is the main reason why machining is kept to a minimum to produce complex and uncommon Neodymium magnets shapes.

7. Plating

In this process the Neodymium magnets are plated with the layers of nickel, copper and nickel.  This is essential to improve the corrosion resistant capacity of the material. A Neodymium magnet with no plating can easily lose their magnetic attribute in the existence of moisture.

8. Magnetization

Here, though the Neodymium magnets have all the property for direction of magnetization, yet they are not at all magnetized. For developing the quality of magnetization, they are exposed to a very strong magnetic strength for a brief moment.  The coil and capacitors used in the magnetizing process are of really of huge voltage enable the material to grow the magnetic field of its own.  

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