The main impact that MagNEO project aspires to achieve is to replace rare earth elements (REE) for permanent magnet production with REE-free AlNiCo (Aluminium, Nickel, Cobalt) alloys which are most promising due to their higher coercivity at elevated temperatures and develop new recycling strategies. In addition, that is going to reduce Europe’s dependence on unstable markets, and it will be an extra push for the attainment of green transition.
Project
Objectives
MagNEO’s objective is robust and sustainable REE-free PM for emergent energy & mobility applications. The concept hinges upon novel compositions of AlNiCo & High Entropy Alloy (HEA) undergoing similar spinodal decompositions, processed by additive manufacturing (AM). The recycling strategies developed will allow environmentally friendly repurposing of disparate metallic constituents, with emphasis on Co recovery.
Design and develop three novel magnetic AlNiCo and HEAs compositions suitable for AM.
Develop a multiscale methodology to select compositions and microstructure with optimized fraction.
Establish and optimize PBF-LB process parameters and build strategies for processing REE-free PMs with controlled grain alignment and orientation under high thermal gradients.
Pilot scale production of new AlNiCo and HEA magnets.
Ensure environmental sustainability by performing a thorough life cycle assessment.
Ensure economic sustainability through Technoeconomic Analysis for manufacturing and production value-chain sustainability.
Methodology
MagNEO methodology is built upon six interconnected main pillars.
Replicate this exceptional performance for AlNiCo-5 through AM at both laboratory and industrial scales.
High-throughput experimental screening will be performed via arc melting.
Process modelling activities of advanced powder atomization, AM-induced microstructural and process modelling, as well as design via topology and Multiphysics optimization.
Lab Scale AM, processing conditions for PBF-LB and post heat AM treatment.
Industrial scale AM and post processing will be scaled up to 150 kg to produce demonstrator magnets ≤1Kg in weight and ≤350 cm3 in volume each, by large scale AM via PBF-LB.
Life Cycle Assessment / Technoeconomic Analysis / Socio-Technological Analysis (LCA/TEA/STA) and strategies for recycling.