Securing DAF Supply Chains with Rare Earth Magnets (Vulcan Elements)

In conjunction with AFRL/RX,  and based on the Phase-I-like preliminary work conducted in Q1 & Q2 2024, Vulcan Elements will translate its work in laboratory development up to pilot scale development and small scale production. AFRL/RX is researching alternative sources of raw material to help address the shortage of domestically produced rare earth elements and magnets. However, AFRL/RX has indicated they lack a robust transition path to bringing alternative sources of rare-earths to production & integration into DAF systems. Working directly with Senior Research Scientists at AFRL/RX, this Direct-to-Phase II work allows Vulcan Elements to design and develop its materials & processes in a way which can qualify these alternative sources as they are discovered. While the entire process of stripacsting up to magnetizing  is crucial to quality, the first half of the process (i.e., stripcasting, hydrogen decrepitation, jet millings, and axial/alignment pressing) has significant metallurgical processes that define how well the resulting material will perform as a magnet. Vulcan Element’s focus under this proposal is to commission & conduct process R&D in a pilot factory capable of producing NdFeB magnets for prototyping. This requires a significant process, metallurgy, and magnetics engineering campaign scale up processes from the laboratory (grams) to pilot scale (kilograms). Currently at TRL4/5 (feasibility study developed and certified by the Department of Energy). Award will get Vulcan Elements to TRL7/8.