"Final Report Summary - ROMEO (Replacement and Original Magnet Engineering Options)
1) The development of several novel microstructural-engineering strategies in order to eliminate, or drastically reduce the heavy rare-earths (HRE) in high-temperature Nd-Fe-B magnets with improved coercivity and retained magnetisation, which will enable them to be used for applications above 100°C.
The first objective (1) was fully matched within the three years duration of the project.
Drastic reduction of the amount of HRE needed to produce permanent magnets was fully achieved in the scope of objective (1), thanks to the invention of a new and innovative method to promote selective formation of a dysprosium-rich phase in the shell of the hard magnetic grains, with no loss in magnetization within the core of the hard magnetic phase. Current technologies use about 10-11 wt% of Dy, whereas with the new technique, only 0.6 wt% Dy is effective. This reduction by a factor of 16 represents a dramatic decrease in cost of the manufactured magnets, which can be estimated to roughly 40% based on the raw material costs in 2015. Furthermore, the new method is cost-effective, eco-efficient and can be easily implemented in industrial production. It was already tested in realistic industrial conditions to set-up a prototype motor for an electric vehicle and a windmill, respectively."
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