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The following article was published in our article directory on July 3, 2014.
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Neodymium Magnets: How they're made

Article Category: Arts and Crafts

Author Name: Nick Bugeja

Manufacturing permanent magnets like rare earth magnets require careful preparation. Nd2Fe14B is the basic compound used for neodymium magnets.

The first step in manufacturing magnets (such as neodymium magnets) is the preparation of certain materials that depend on temperature. A common combination is Cobalt and Dysprosium since particular replacements can affect the coercivity and strength of the magnet. When Iron is replaced with Cobalt, there is an increase in heat stability to a certain extent, but the coercivity lowers. When Dysprosium replaces Neodymium, coercivity increases but the magnet's strength decreases.

The second step is melting. Here, the chemical reaction is observed, which takes place in a vacuum induction furnace to prevent contaminants from getting involved in the reaction.

The third step is milling. This procedure is necessary to turn the material into particles of powder.

The powder is then pressed. It is solidified to facilitate the direction of magnetization. In the die-upsetting technique, the powder is pressed into a solid form at about 725 degrees Celsius using a die. A second die is used where the solid is further compressed to a wider but shorter shape. This way, the direction of magnetization is aligned parallel to the pressing direction on the die. For other shapes like disc magnets and rod magnets, there are other methods practiced that create a magnetic field to align the particles according to the preferred direction when pressed.

A process known in powder metallurgy is sintering (compressing materials at much higher temperatures), in which temperatures of 1080 degrees Celsius below their melting points are reached.

After that, machining takes place to have the sintered magnets cut. Other magnets like disc magnets or rod magnets are shaped through grinding, while less common and more complex figures are shaped with electric discharge machining (EDM). This is a process that needs cautious operating because lost material cannot be recycled, and material cost is high.

The next step is plating. This involves a three-layered electroplating with nickel, copper, and nickel again. This has been a highly practiced process because neodymium magnets are highly prone to oxidation and corrosion. With moisture, magnets will easily lose their magnetic properties.

The process of magnetization will need a preferred direction but the magnets are not magnetized. For a short time, the magnets will be exposed to a very powerful magnetic field.

The neodymium magnets (or other similar magnets) are then finally examined for their properties, and then graded for quality. The dimensions are confirmed by a digital measuring projector, while the plating quality is verified by a coating measurement system with the use of x-ray fluorescence technology.

With the employment of powder metallurgical methods, neodymium magnets are manufactured without actually trying to machine them. These magnets are not as strong as they seem, despite the ceramic or metallic appearance. Although it is possible to form magnets into different shapes, sometimes complex ones, it is best to form simpler shapes so as to organize the direction of their magnetization. Along with the appearance of the magnet, it is also important to consider the composition of the magnet to secure its magnetic strength.

Another known production procedure is the rapid solidification or the bonded magnet process, which is equally practiced like the classical powder metallurgy process.

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

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