Project
Technology

• Implementing HPTP melting of PMs to reduce material losses by 15% compared to vacuum induction furnaces.
• Strip-casting the resulting PM-based metal alloy ingots into flakes.

• Performing hydrogen decrepitation of the strip-cast flakes.
• Jet-milling flakes into fine microcrystalline powders.

• Implementing the near-net-shape process through Powder Injection Moulding (PIM), noted for its high maturity and large production capacity.
• Controlling powder contamination (carbon and oxygen) during feedstock blending and debinding with a protective coating on powders.
• Enabling the production of non-conventional, functional shapes through near-net-shape magnet manufacturing.

EVTM’s new rotor design optimisation

• Reducing PM mass required per new motor by increasing the kW/kg of PM.
• Facilitating reversible assembly of PM thanks to geometrical details.
• Optimising magnets and rotor shape to enhance performance.

• Conducting a detailed review of collection schemes, expected tonnages, and logistics.
• Assisting in issuing guidelines for responsible sourcing to improve the EU principles for sustainable raw materials.

• Employing a unique thermo-mechanical technique to:
  • Maximise the portion of PM scrap suitable for the magnet to alloy route.
  • Minimise oxidation reactions and reduce impurities from the coating and ceramic bonding glue.
• Designing new magnets and rotor to facilitate extraction by eliminating PM gluing.

• Developing characterisation and decision protocols for directing EoL equipment and components to their ideal recycling route.
• Separating and sorting EoL magnets with high contents of HREE (3-6%).
• Pre-treating sorted magnets to improve the subsequent re-melting process.
• Achieving improved yield of the melting route of up to 80-90% with a high value of HREE (Dysprosium and Terbium) alloys that are 3 to 20 times more expensive than LREE (Neodymium and Praseodymium).

• Advantage
  • Enables the refining of the microstructure of the ribbons/flakes, potentially enhancing the magnetic properties of PMs.
• Environmental competitiveness
  • Conserves up to 70% of the REE in the metallic form, significantly reducing the high energy typically required for their reduction.
  • Eliminates the need for separation of constituting elements (Nd-Dy-Fe-B), thus avoiding polluting processes.
• Economic competitiveness
  • Increases the yield, making it more productive.
  • Utilises conventional strip casting equipment already available in magnet manufacturing plants, which offers savings on implementation costs.
  • Enables the incorporation of non-critical primary sources (Ce and La) into different alloys, leveraging cheaper and easier-to-source materials, thereby reducing costs.