High toughness rare earth-based Fibrous Monolith Permanent Magnets

In this phase I STTR program, Advanced Ceramics Research, Inc. (ACR) and the University of Delaware (UD) propose the development of an innovative process for high energy product rare earth-based permanent magnets with improved toughness based on ACR'spatented Fibrous Monolith (FM) and the UD's Automated Tow Placement (ATP) processes. The novel combination of high-toughness NdFeB-based FM materials with fiber reinforcement will provide a unique synergy where the FM will provide improved toughness,while the fiber reinforcement will provide additional mechanical strengthening and integrity to the permanent magnet materials. UD will provide the materials characterization and processing support to ACR for structural design of the components. In thephase I program, the ACR led team will prove the concept and fabricate permanent magnet composite coupons with fiber reinforcement for mechanical testing and magnetic property characterization at UD. Additionally, ACR-led team will develop guidelines andprocedures for optimizing the performance of permanent magnet materials and provide a preliminary cost/economic analysis for prototype permanent magnet components. In the phase II program, the ACR led team will scale up the manufacturing process forfabricating full-scale components.Commercial potential exists for high-performance permanent magnets for use in aircraft engine bearing assemblies and at room temperature for electric propulsion systems needed in Unmanned Underwater Vehicles (UUV) andtorpedoes. In addition to DoD applications, the newly developed superior magnets could be used in commercial electric vehicles, hybrid electric vehicles and factory machines, and will contribute to a reduction in world energy consumption and carbon dioxideemission.