High Performance PrFeB Permanent Magnets Through Novel Pulse Alignment and Compaction Method for Cryogenic Permanent Magnet Undulators (CPMU)

There is a great demand for high energy advanced photons in many fundamental scientific disciplines and applications like undulators. Magnets based on PrFeB chemistry are most suitable for cryogenically operated undulators. Prior to our Phase I project, there were no development efforts for a United States manufacturing base for PrFeB magnets. The first objective is to process the best performing PrFeB magnets using an innovative in-situ pulse alignment/compaction method along with optimizing the magnet composition as well as the sintering and heat treating schedules. The next objective is to establish a United States manufacturing base with Arnold Magnetics to produce these permanent magnets. In Phase I we demonstrated the feasibility of in-situ pulse alignment/compaction method with a base composition, sinter, and heat treat conditions. We compared magnets fabricated using pulse and conventional methods to the best reported values. The remanence Br and intrinsic coercivity were good and the path for further improvement was identified. In Phase II we will process the best magnets through optimization of pulse and conventional compaction methods and then test the magnet performance including field homogeneity for use in CPMU. We will study the process costs and performance benefits to make a business case for a United States manufacturing base. We will manufacture 48 magnets for an undulator assembly. Commercial Applications and Other Benefits: Cryogenic undulators are needed for national (DOE) and international photon facilities and free electron lasers. Undulators impact medical and energy sectors. A United States rare earth magnet manufacturing base will create new high paying jobs for magnet manufacturing by expanding into the wind and hybrid electric motor market.