Sintered Neo Replacement:Dysprosium-free Rare Earth Permanent Magnet Motors

Sintered Neo Replacement

• Fundamentals in dysprosium (Dy) market will result in significantly higher prices

– Increasing demand due to growth in sintered Nd market

– Insufficient supply

• When possible, magnet users should design applications with magnets without Dy

– Magnets using MQPTM grades do not rely on Dy

• Application performance is comparable and can be optimized if MQPTM is “designed in”

Rising prices of rare earth metals:Soaring prices of Dy

Escalating Price of Dy:Fundamental supply-demand imbalance

High demand High demand in Dy rich sintered neo applications Low outputLow output

*Source:National Development and Reform Commission (NDRC) Report April 2011

Estimated Production in 2010*

Lanthanum

24.6%

Cerium

29.0%Praseodymium

5.4%

Neodymium

20.7%

Samarium

2.0%

Europium

1.0%

Gadolinium

1.6%

Terbium

0.6%

Dysprosium

2.4%

Erbium

1.1%

Yttrium

11.7%

Dy Rich Sintered Applications

Technology Assumption Low Penetration High Penetration

Deployment in

2025

Wind Onshore Wind Turbine Additional Capacity (GW) 23.6 48.6

Wind Offshore Wind Turbines Additional Capacity (GW) 4.9 17

Vehicles Sales of Hybrid Electric Vehicles (HEVs) (millions) 4.2 19.1

Vehicles Sales of Plug-in Hybrid Electric Vehicles (PHEVs) (millions) 0.002 13.2

Vehicles Sales of All Electric Vehicles (AEVs) (millions) 0.001 4.6

Market Share

Wind Onshore Wind Turbines using RE Magnets 10% 25%

Wind Offshore Wind Turbines using RE Magnets 10% 75%

Vehicles HEVs, PHEVs, and AEVs using RE Magnet Motors 100% 100%

Technology Assumption Low Intensity High Intensity

Materials

Intensity

Wind Average Weight of Magnets per MW (kgs) 400 600

Vehicles Average Weight of Magnets per vehicle (kgs) 1 2

Wind and

Vehicles% Weight of Magnets that is Neodymium 31% 31%

Wind and

Vehicles% Weight of Magnets that is Dysprosium 5.50% 5.50%

Source: Critical Materials Strategy by U.S Department of Energy (Dec 2010)http://www.energy.psu.edu/oeo/ree/reports/criticalmaterialsstrategy121710.pdf

Current Rare Earth Types and Content

Source: Critical Materials Strategy by U.S Department of Energy (Dec 2010)http://www.energy.psu.edu/oeo/ree/reports/criticalmaterialsstrategy121710.pdf

Low levels of Dy occurrence

Low levels of Dy present

Estimated Production in 2010*

*Source:National Development and Reform Commission (NDRC) Report April 2011

Lanthanum

24.6%

Cerium

29.0%Praseodymium

5.4%

Neodymium

20.7%

Samarium

2.0%

Europium

1.0%

Gadolinium

1.6%

Terbium

0.6%

Dysprosium

2.4%

Erbium

1.1%

Yttrium

11.7%

Possible new sources of Rare Earths:Dy contents are low

Assumed Additional Production by 2015 Total

Additional

Production by

2015

Mountain Pass

(USA)

Mt. Weld

(Australia)

Nolans Bore

(Australia)

Nechalaco

(Canada)

Dong Pao

(Vietnam)

Hoidas Lake

(Canada)

Dubbo Zirconia

(Australia)

Lanthanum 6,640 3,840 2,000 845 1,620 594 585 16,124

Cerium 9,820 6,855 4,820 2,070 2,520 1,368 1,101 28,554

Praseodymium 860 810 590 240 200 174 120 2,994

Neodymium 2,400 2,790 2,150 935 535 657 423 9,890

Samarium 160 360 240 175 45 87 75 1,142

Europium 20 90 40 20 - 18 3 191

Gadolinium 40 150 100 145 - 39 63 537

Terbium - 15 10 90 - 3 9 127

Dysprosium - 30 30 35 - 12 60 167

Yttrium 20 60 - 370 35 39 474 998

TOTAL 19,960 15,000 9,980 4,925 4,955 2,991 2,913 60,724

Source: Critical Materials Strategy by U.S Department of Energy (Dec 2010)http://www.energy.psu.edu/oeo/ree/reports/criticalmaterialsstrategy121710.pdf

Why does Sintered Neo need Dy?

• Sintered neo is much more inclined to have a knee in the second quadrant engineering curve at elevated temperature

– Due to high remanence

values of sintered neo

– Results in irreversible losses

in motor

• Compensation for this knee, motor companies could

– Increase the magnet length

– Adding Dy to enhance

coercivity

Typical Sintered Neo Alloy composition

Type T.R.E NdPr Dy Gd Tb Fe Co B Al

N35H 32.4 27.23 3.3 1.9 0 64.4 1 1 1

N35SH 33 29.64 3.4 0 0 64.8 0 1.1 1

N35UH 32.1 26.92 5 0.2 0 65 1 1 1

N38H 32.2 29.04 3.2 0 0 65.1 1 1 0

N38SH 31.9 28.29 3.6 0 0 65.4 1 1 1

N38UH 31.7 25.62 6.1 0 0 65.8 0.9 1 0

N42H 31 29.3 1.8 0 0 66.5 0.7 1 0

N42SH 30.4 26.66 3.3 0 0.4 66.9 1 1 0

N42UH 31.7 27.24 3.8 0 0.7 65.8 0.9 1 0

N45H 31.4 29.45 2 0 0 66.1 0.9 1 0

N45SH 30 27.06 0.8 0 2.1 67.4 0.9 1 0

N45UH 30.1 26.61 0.8 0 2.7 67.3 0.9 1 0

MQP-B 25.4 25.41 0 - - 73.4 - 1 -

� Typical sintered Nd grades contain up to 6% of Dy

Advantages of Bonded Neo

• MQPTM has very good linearity in the second quadrant engineering curve up to temperatures as high as 150-180oC

• Able to achieve equivalent performance

• No significant increase in motor size

• All MQPTM grades are Dy free!

0

1

2

3

4

5

6

7

8

-7 -6 -5 -4 -3 -2 -1 0

B (

kG

)

H (kOe)

25C-MQP-B+-20056 125C-MQP-B+-20056 25C-MQP-14-12 125C-MQP-14-12

Load line at no-loadLoad line at stall

www.mqitechnology.com

Copyright © 2011 Magnequench Neo Powders Pte Ltd

CASE STUDYCASE STUDY

Case Study 1: Comparison of the Sintered Neo and Bonded Neo based Motors

Parameter4-Pole PMDC Motor with Sintered Neo Magnets

4-Pole PMDC motor with Bonded Neo Magnets

Type of Magnet4-Arc Sintered neo

(N35SH)

Isotropic Bonded Neo

(MQP-14-12)

Total motor weight (gm) 107.80 143.34

Length of the motor (mm) 10.00 12.00

Overall diameter (mm) 42.00 46.75

Total copper weight (gm) 12.70 23.80

Total magnet weight (gm) 14.20 24.94

Length of Air gap (mm) 0.80 0.80

Current at 80 mN-m (A) 11.06 10.20

Efficiency at 80 mN-m (%) 73.13 75.27

Case Study 1:Chemical Composition and Magnet Characteristics for Sintered Neo Magnet

Element Nd Tb La Ce Pr Sm Dy Gd T.R.E

% 18.731 0.151 0 0.031 5.862 0.026 2.491 1.680 28.972

ICP Test Result

Case Study 1: Comparison of Key Physical Dimensions for the Sintered Neo and Bonded Neo based Motors

Sintered Neo Motor Bonded Neo Motor

Case Study 1: Comparison of Motor Characteristics for the Sintered Neo and Bonded Neo based Motors

Torque-efficiency and Torque-output power characteristics

Torque-speed and Torque-current characteristics

Case Study 1: Comparison of Key Physical Parameters and Cost for the Sintered Neo and Bonded Neo based Motors

Case Study 2: Comparison of the Sintered Neo and Bonded Neo based Motors

Parameter4-Pole PMDC Motor with Sintered Neo

Magnets

4-Pole PMDC Motor with Sintered Neo

Magnets

4-Pole PMDC motor with Bonded Neo

Magnets

Type of Magnet4-Arc Sintered neo

(N35SH)4-Arc Sintered neo

(N35)Isotropic Bonded Neo

(MQP-B+-20056)

Dy content ~3% 0-0.5% 0%

Total motor weight (gm) 314.90 451.4 412.50

Length of the motor (mm) 18.00 23.00 20.00

Overall diameter (mm) 57.50 60.72 63.90

Total copper weight (gm) 29.80 21.3 57.10

Total magnet weight (gm) 29.10 56.5 37.30

Length of Air gap (mm) 0.55 0.55 0.55

Current at 220 mN-m (A) 11.08 10.55 11.21

Efficiency at 220 mN-m (%) 73.76 74.59 74.09

Case Study 2: Comparison of Key Physical Dimensions for the Sintered Neo and Bonded Neo based Motors

Bonded Neo MotorSintered Neo (35SH) Sintered Neo (N35)

Case Study 2: Comparison of Motor Characteristics for the Sintered Neo and Bonded Neo based Motors

Torque-efficiency and Torque-output power characteristics

Torque-speed and Torque-current characteristics

Case Study 2: Comparison of Key Physical Parameters and Cost for the Sintered Neo and Bonded Neo based Motors

Case Study-3 – Comparison of the Sintered Neo and Bonded Neo based Motors

Parameter4-Pole PMDC Motor with Sintered Neo

Magnets

4-Pole PMDC motor with Bonded Neo

Magnets

Type of Magnet4-Arc Sintered neo (N27SH or N30SH)

Isotropic Bonded Neo (MQP-14-12)

Total motor weight (gm) 204.35 237.00

Length of the motor (mm) 15.50 19.25

Overall diameter (mm) 44.10 49.79

Total copper weight (gm) 28.09 18.60

Total magnet weight (gm) 18.47 39.80

Length of Air gap (mm) 0.57 0.57

Current at 190 mN-m (A) 27.08 26.99

Efficiency at 190 mN-m (%) 74.30 73.04

Case Study 3:Chemical Composition and Magnet Characteristics for Sintered Neo Magnet

Element Nd La Ce Pr Sm Dy Tb Gd T.R.E

% 21.204 0.004 0.028 6.047 0.000 4.087 0.034 0.109 31.479

ICP Test Result

Case Study 3: Comparison of Key Physical Dimensions for the Sintered Neo and Bonded Neo based Motors

Sintered Neo Motor Bonded Neo Motor

Case Study 3: Comparison of Motor Characteristics for the Sintered Neo and Bonded Neo based Motors

Torque-efficiency and Torque-output power characteristics

Torque-speed and Torque-current characteristics

Case Study 3: Comparison of Key Physical Parameters and Cost for the Sintered Neo and Bonded Neo based Motors