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The following article was published in our article directory on June 27, 2014.
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The Making of Rare Earth Magnets

Article Category: Shopping

Author Name: Nick Bugeja

Rare earth magnets are strong permanent magnets that yield high magnetic fields. Their great strength is due to an advanced and intricate arrangement of atomic particles and their electron spin. This method of manufacturing is licensed. Restrictive patents have recently begun to expire which has led to market growth and the availability of these rare earth magnets.

The first in the long process of manufacturing the magnets is mining. Rare earth magnets contain a lot of metals and all of those come from the ground. When the raw material is obtained, it is ground to a powder and is combined to produce the different grades of materials. These varying mixtures lead to different magnetic properties for each material.

The next step would be to press the powder. There are three main ways to press the powder, and those are die pressing, transverse pressing, and isostatic pressing. Die pressing requires tooling to create a hole that is a bit bigger than the required form . This is because the process of sintering would make the magnet shrink. The powder is inserted into the hole and is then compacted with the use of a magnetic field applied externally. This field is applied either parallel or perpendicular to the compacting force. Transverse pressing undergoes a similar method, but gives higher magnetic properties. In isostatic pressing, the powder is placed in a rubber mold, then that mold is placed in a large container filled with fluid. The pressure of the fluid is then increased. An external magnetic field is again utilized, but this time the powder is compacted from all sides.

The next step in the making of rare earth magnets requires the use of a machine to get the required tolerances. The standard tolerances are +/- 0.1mm, but it can go up to +/- 0.5mm. Higher tolerances may be possible depending on the shape and size of the magnet; although, this may not actually be achievable. Once the dimensions of the magnet are made through the machine, it is then given a protective coating.

The magnet must be cleaned in order to remove any powder from the machining process. Afterwards , it is thoroughly dried then coated. It is vital that the magnet undergoes a thorough drying because if not, the water would remain in the plated magnet which will cause the magnet to corrode from the inside out. For the plate, there are different types available: epoxy, zinc, gold, silver, titanium, chrome, everlube, tin, PTFE, nickel-copper-nickel, zinc chromate, and uncoated. There are also other variations of the nickel-copper-nickel. It is not advisable to have a magnet that is without a protective layer.

The last step in the process is the magnetization. After plating, the magnet is then placed in a solenoid coil energised to make a field that is higher than the magnet's Hci. The rare earth magnets must sometimes be held physically in place because it may respond to magnetizing pulse being applied and may ricochet out of the coil. The magnets may only be magnetized in the direction of alignment of the structure.

Keywords: rare earth magnets, neodymium magnets, disc magnets, n52 magnets

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