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A research team has developed an advanced magnet production technique that could improve the performance and efficiency of electric motors used in clean energy applications. The new method combines spark plasma sintering with grain boundary diffusion, resulting in permanent magnets that are both lighter and more heat-resistant—key requirements for technologies like electric vehicles (EVs), wind turbines, and industrial robots.
The core issue the team aimed to address lies in the current limitations of neodymium-based (Nd-Fe-B) magnets, which power most EV motors and other high-performance systems. These magnets tend to lose strength at high temperatures, prompting manufacturers to add rare elements such as terbium and dysprosium. While effective, these materials are expensive and in limited supply.
Grain boundary diffusion—a technique used to apply small amounts of these rare-earth elements to the magnet’s surface—can boost thermal resistance. However, its effectiveness is limited in thicker magnets, as the diffusion tends to remain near the surface.
To solve this, the researchers introduced spark plasma sintering, a fabrication process that applies pressure and pulsed electrical current to powders to form solid materials. By incorporating the rare-earth diffusion agents during the sintering stage, the team succeeded in achieving deeper and more uniform diffusion. This created a core–shell structure, where the magnet exhibits enhanced performance throughout, rather than just at the surface.
According to TechXplore, this approach not only improves the diffusion depth but also increases efficiency, allowing for greater magnetic strength with the same amount of rare-earth material. The result is a smaller, lighter magnet capable of maintaining performance in high-temperature conditions—ideal for next-generation electric powertrains and compact turbine systems.
The findings represent a significant step toward more sustainable and cost-effective magnet production for green industries. By increasing diffusion efficiency and reducing dependence on scarce materials, the process could support the broader adoption of renewable energy and electrified transportation systems.
Researchers believe the same principles could be applied to larger magnets and scaled for industrial use.
The research was published in the Alloys and Compounds Journal.
