# Patent

## Title
Magnet construction by combustion driven high compaction

## Abstract

A neo magnet is constructed by mixing a neo magnet powder with about 1% added two-part electrical insulating resin powder. The mixed powders are placed in a die and precompacted under about 20 tsi when filling a combustion chamber with a pressurized combustible gas and air mixture. The gas is ignited and rapidly drives a punch in to the die forming a solid magnet having a density of 6.1 g/cm3 or more. The solid magnet is heat treated to cure the resin and is coated with a polymer, zinc, aluminum or gold. Before precompacting a lubricated core rod in place in the die producing a thin-walled, neo ring magnet having a length to wall thickness aspect ratio.

## Background
This application claims the benefit of U.S. Provisional Application No. 61/396,231, filed May 24, 2010, which is hereby incorporated by reference in its entirety as if fully set forth herein.


SUMMARY OF THE INVENTION
Utron's Combustion Driven Compaction (CDC) uses controlled release of chemical energy from combustion of natural gas and air to compact magnetic powders up to 150 tsi for obtaining net shape high-density pressed thermally processed final parts for high performance permanent and soft magnets. FIG. 1 shows a CDC, with a combustion chamber on the right.
Traditional powder compaction molding (PM) limited to 50-55 tsi and metal injection molding (MIM) produce lower density magnets (e.g., 5.85 to 6 g/cc) with correspondingly lower magnetic properties. Conventional low pressure powder compaction or injection molding lead to relatively higher % of geometrical dimensional changes.
Utron's CDC press operation fills a die with magnetic powder, fills a chamber to high pressure with a mixture of natural gas and air. As the chamber is being filled, the piston or ram moves, pre-compressing and removing entrapped air from the powder. The gas supply is closed, and an ignition stimulus is applied, causing the pressure in the chamber to rise dramatically, further compressing the metal powder to its final net shape. Utron's basic CDC compaction process and CDC 300, 400 and 1000 ton presses compaction presses are manual or automated to fabricate 1 to 6 magnets/minute, depending on part geometry. The Utron CDC magnet compaction process provides high compaction pressures up to 150 tsi, resulting in very high-density magnets with improved properties. In addition to the unique loading sequence and high tonnage the process occurs over a few hundred milliseconds. A typical UTRON's CDC produced load shown in FIG. 3a illustrates the faster process cycle time of milliseconds. Conventional magnetic powder mechanical and hydraulic pressing is limited to  ̃50-55 tsi with lower as-pressed green densities followed by large shrinkages.
Permanent magnetic materials are developed for their property attributes of high induction, high resistance to demagnetization, and maximum energy content. Permanent magnets are primarily used to produce magnetic flux fields, which are a form of potential energy). Table 1a provides an overview of several end use applications. Table 1b provides select magnetic property data of commonly used permanent magnets, including those of bonded NdFeB magnets containing resins manufactured by conventional methods of manufacturing. FIG. 3b shows the commonly used magnetic geometries. FIG. 3c shows the importance of NdFeB based magnets for obtaining better magnetic strength properties.
Magnetic induction (Br) is controlled and limited by alloy composition. Resistance to demagnetization (coercive force Hc) is conditioned to less extent by composition than by shape, or crystal anisotropies, precipitations, strains and other imperfections, including finer particle sizes. Samarium cobalt-based rare earth magnets, as indicated in Table 1b, are for higher temperature use as compared to NdFeB type magnets. Rare earth magnets are the most sturdy type of permanent magnets available at present for various end use applications. These permanent magnets are manufactured by us using several rare earth elements. Owing to the brittle nature of these magnets, especially without any resins, many powder compaction methods involve resin-containing rare earth compounds (e.g., bonded neo compositions have epoxy or similar resins added in various proportions). Conventional metal injection molding and lower pressure powder metallurgical (PM) compaction methods of these bonded magnets are known to provide relatively lower as-pressed/thermally processed densities (e.g., 5.85 to 6 g/cc are common, depending on the bonded neo compositions, type of resins, lubricant additives etc.), with correspondingly relatively lower magnetic properties.
So far in the previous arts as reported in the literature around the world, there are number of attempts by both academia and industry to develop rapidly solidified Nd—Fe-B magnet powders using a variety of rapid solidification followed by suitable milling/grinding etc. However, there has not been any breakthrough scientifically to further advance developing competitive alloy mixes, or compacting mixes uniquely using controlled high pressure above >50-55 tsi and rapid cycle times or milliseconds of pressing cycle time.
Needs exist for improved magnets.
These and further and other objects and features of the invention are apparent in the disclosure, which includes the above and ongoing written specification, with the claims and the drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows a CDC combustion driven compaction chamber on the left and shows an actual CDC chamber on the right.
FIG. 2 shows three CDC chambers producing varied forces of compaction.
FIG. 3a shows graphs of CDC press load force vs. time in micro seconds and magnet densities compared to load forces as well as samples of parts produced by Utron's CDC.
FIG. 3b shows permanent magnet geometries.
FIG. 3c shows improvements 47 in magnets in the last century.
FIG. 4 shows as-pressed green densities of CDC high pressure compacted samples of broad spectrum of magnetic powders.
FIG. 4b shows the percentage of springback of CDC high pressure compacted magnetic materials.
FIG. 4c shows the percent of springback of as-pressed CDC magnetic cylindrical disk samples.
FIG. 4d shows CDC high pressure compacted sample #549 with an aspect ratio of 3.21
FIG. 4e shows sample #792 with an aspect ratio of 2.18.
FIG. 4f shows sample #793 with an aspect ratio of 1.99.
FIG. 4g shows sample #794 with an aspect ratio of 1.53.
FIG. 4h shows sample #795 with an aspect ratio of 1.82.
FIG. 5a shows significant improvement of permeabiloity and Q-factor in Utron compacted CDC nanocomposite soft magnetic Fe—Ni with 3 nm SiO2 powders with higher part densities of 5.81 to 6.15 compared to the properties of traditional CoNi-Ferrite materials.
FIG. 5b shows dynamic hysteresis loops of CDC compacted soft magnetic nanocomposite materials up to 1 MHz for FeNi/SiO2 with density of 5.81 g/cc of the same materials with small eddy current losses in the frequency ranges.
FIG. 6 shows improved BHmax properties of CDC higher pressured compacted high temperature permanent magnetic materials of SmCo/Fe composites.
FIG. 7 shows CDC high pressure compacted and thermally cured sample #s 2656, 2664, 2665 and 2666.
FIG. 8 shows CDC low pressure compacted and thermally cured sample #s 2672, 2673, 2674 and 2675.
FIG. 9 shows CDC compacted and thermally cured sample #s 2672, 2673, 2674, 2675, 2565, 2664, 2665 and 2666.
FIG. 10 shows that higher CDC compaction pressure samples have overall better magnetic properties and density than lower CDC compaction pressure samples.
FIG. 11 shows magnetic properties of Utron's kinetic higher performance bonded neo magnets (HPM Series).
FIG. 12 shows selected magnetic properties of CDC compacted bonded neo magnets.
FIG. 13 shows CDC higher pressure compacted and processed magnetic outer ring/steel core assembly for potential electric motor drive applications.
FIG. 14 shows powder fill position for thin walled magnet fabrication.
FIG. 15 shows a powder pressing position to fabricate the thin walled net shape CDC magnet.
FIG. 16 shows CDC high pressure copacted net shape magnet part ejection.
FIG. 17 shows a view of the die cavity with lubricated core rod installed in view of the tooling in the 300 ton CDC press.
FIG. 18 shows a view of the die cavity with bonded neo powder already filled in the annular hollow region of the core rod covered by upper punch (hollow cylinder) in assembled view of the 300 ton CDC press.
FIG. 19 shows a view of the die cavity with bonded neo powder already filled in the annular hollow region on the core red covered by upper punch (hollow cylinder) as shown in the view of the 300 ton CDC press.
FIG. 20 shows a view of the CDChigh pressure compacted bonded neo thin walled ring in the core rod after the die cavity is lowered just before part removal.
FIG. 21 shows a view of the CDC high pressure compacted bonded neo thin walled ring in the core rod just before part removal.
FIG. 22 shows a view of the CDC high pressure compacted bonded neo thin walled ring in the core ring rod after disengaging from the piston of the CDC combustion chamber just before part removal.
FIG. 23 shows CDC high pressure compaction loading profile for bonded neo thin walled ring.
FIG. 24a shows CDC high pressure compaction loading profile for bonded neo thin walled ring.
FIG. 24b shows CDC high pressure compaction loading profile for bonded neo thin walled ring.
FIG. 24c shows CDC high pressure compaction loading profile for bonded neo thin walled ring.
FIG. 25 shows a view of the CDC high pressure compacted bonded neo thin walled ring at 95 tsi after the part removal from the core rod.
FIG. 26 shows angular side views of the successful CDC high pressure compacted bonded neo thin walled ring sample with higher as-pressed green densities without any cracking after compacting at  ̃140-150 tsi after the parts are removed from the core rod.
FIG. 27 shows the top view of a successful CDC high pressure compacted bonded neo thin walled ring sample with higher as-pressed green densities without any cracking after compacting at  ̃140-150 tsi after the parts are removed from the core rod.
FIG. 28 shows successful reproducible CDChigh pressure compacted bonded NdFeB—alloy magnet-thin walled ring samples after the parts are removed from the core rod.



DETAILED DESCRIPTION OF THE DRAWINGS
As schematically shown in the left of FIG. 1, a CDC press 10 has a combustion chamber 11 in a housing 13, a gas inlet 15 and electric ignition 17 that may be replaced by a laser igniter. Natural gas (CH4) and air fill the chamber 11 at high pressure. A piston 21 and coupled male die 23 form the single moving part 25. Powder 27 is placed in the female die 29.
As the gas 19 fills the chamber at high pressure, the piston 21 and moves the punch or male die 23 into the female die 29, partially compressing the powder 27. Ignition 17 provides a spark or a sapphire window admits a laser beam to ignite and combust the gas and air 19 in combustion chamber 11. The combustion products rapidly drive the piston 21 and the male die 23 into the female die, compressing the powder with several hundreds of force at pressures up to 150 tsi or more.
The combustion chamber housing 13 gas inlet 15 and electric ignition 17 are shown at the right of FIG. 1.
FIG. 2 shows presses 31, 33 and 35 of 300 tons, respectively. Combustion chamber housings 13 are shown at the tops of the presses and male and female dies 23, 29 are shown within the enclosures 37.
This invention provides magnet manufacture using higher pressure up to 150 tsi combustion driven compaction methods to improve not only the densification and magnetic properties. The invention uses innovative material compositions of baseline NdFeB based magnetic powders with up to 2% of other suitable type of epoxy resin additives. As well as the magnetic properties and net-shape attributes the invention fabricates complex shapes such as thin walled, e.g. 0.060 inch wall thickness, using innovative tooling and fabrication techniques.
Bonded NdFeB magnets are strong magnets which are used for various applications such as sensors, electronics, loud speakers, and in large industries. The magnets are manufactured by mixing powder with resin, which is further processed to form the magnets. The epoxy resin is used for compression molding. Using injection molding, large volumes of magnets are produced; however the magnetic value of the magnets so produced are lower. Density of those magnets produced by injection molding of about 5.8 g/cc-5.85 g/cc is typical, as compared to magnets made with compression molding using hydraulic or mechanical pressing methods. At relatively low compaction pressures of about <50-55 tsi about e.g. 6 g/cc is typical because of their relatively low density.
After the new CDC compaction, the surfaces are treated with epoxy coating or nickel-plating to prevent corrosion. To keep the bonded neodymium magnets in good condition, use along with acid, alkali, organic solvent or electrolytes must be minimized. The immersion of a magnet in water or oil may also affect its magnetism. Although bonded NdFeB magnets with protective resins are fairly stable, as compared to the bonded magnets without the resins, the bonded magnets should also be not used in spaces filled with hydrogen, corrosive gases and radioactive rays, as a safety precaution.
The new CDC compacted bonded neodymium magnets have many advantages; The magnets are stable and very efficient. The magnets and other parts may be formed together in a single step. For multi polar applications, there is a free choice of magnetizing direction. The magnets have high dimensional accuracy and are available in different shapes and sizes. The magnets have high resistance to atmospheric corrosion and have the highest magnetic properties among other isotropic magnets.
To improve the corrosion resistance, some bonded neo and other permanent magnets are coated with epoxy, zinc, nickel or gold, and such protection also provides extra firmness.
These magnets are widely used in computer hard drives, fishing reel brakes, audio speakers, bicycle dynamos, and more products. On a relative cost basis, neodymium based magnets are relatively lower in cost as compared to samarium-cobalt alloys due to their complex manufacturing process and their special quality to withstand high temperatures. Commonly fabricated shapes of permanent magnets such as short cylindrical slugs, rings, long cylinder, blocks, segmented shape etc. are shown in FIG. 3b. 
Bonded neodymium-iron-boron magnets are of great value and interest due to their uses for several electrical motors and other applications. Bonded neodymium has unique physical and magnetic characteristics, many of which can be advantageous to a motor's size and performance. Although each motor has its own parameters to fulfill, technical strategies and efforts have generally been steered along the following areas to demonstrate how bonded neodymium can be used to reduce weight, reduced size, improve efficiency, improve performance, Reduce costs and lower eddy current losses.
In many applications, traditional ferrite motors have been replaced with bonded neo magnets, due to their improved magnetic performance and weight reduction, which are attractive for automotive components and other applications as indicated in Table 1a. There are numerous sensors, brushless DC electric motors and other applications in which thin walled magnets are used as well as for fabricating rotors with magnets as one assembly. We have successfully fabricated not only permanent magnets of various materials and compositions but also rotor-magnet assemblies using CDC higher pressure compaction.
Bonded magnet materials can be created through injection molding and can be made from NdFeB, strontium ferrite or a combination of the two. Bonded magnets that are created through injection molding can be molded into complex shapes and also can be molded directly onto components. Bonded magnets also can be created through the process of compression bonding which offer higher magnetic output but are limited to simpler geometries than injection molded materials. Compression bonded magnets can be made from either NdFeB or SmCo powders.
Injection molded neo magnets binders including Nylon/PPS/polyamide have a temperature range of −40 deg C. to 180 deg C., tight tolerances off the tool and reasonable mechanical strength properties.
Compression bonded neo magnets have higher magnetic strength due to higher magnetic particle density. Epoxy binder provides resistance to normal industrial solvents and automotive fluids. Epoxy coating is done after manufacturing to prevent oxidation. Compression bonded neo magnets typically operate in the temperature range of −40 deg C. to 165 deg C., provide tight tolerances off the tool and have better mechanical strength properties than injection molded magnets. Epoxy is a better polymer matrix choice for bonded magnets due to epoxy's unique bonding, curability at low temperatures and strength properties.
Bonded magnet materials are isotropic and can be magnetized in any direction, have a wide range of existing tool sizes and are available in rings, discs and rectangles. Existing multipole magnetizing fixtures provide quick prototyping. Bonded magnets are easily machined. Multipole rings simplify assembly verses using arc segments.
The new invention provides improved results of CDC compacted and processed bonded Nd—Fe-B magnets and their unique improved densification, and higher remnance, coercivity and combined products as compared to those obtained by conventional lower density (5.85 to 6 g/cc) bonded magnets.
CDC higher pressure powder compaction provides many advantages. The higher pressure combustion driven powder compaction (CDC) provides >50 tsi up to 150 tsi and has several advantages as compared to traditional low pressure powder pressing methods. The CDC magnet production employs chemical to mechanical energy conversion (FIG. 1) using commonly available chemicals, natural gas or methane and air, to obtain controlled combustion for pressing parts at higher pressures up to 150 tsi. Much higher pressed green and sintered part densities 40 are obtained using compact equipment, providing gentler, smoother and continuous dynamic loading cycles with milliseconds 41 pressing time duration shown in FIG. 3a. CDC compaction provides pressed parts 43 in near net shape and assembled shaping ability for variety of materials including single materials 43 as shown in FIGS. 3a and 3b. FIG. 3c shows improvements 47 in magnets in the last century. The CDC magnet manufacture provides faster process time milliseconds of compaction and improved density of the parts with unique CDC loading cycles and amenability to make simple to complex parts as shown in the figures. The results are much less part shrinkage, for example 50% lower than possible by traditional processing methods. Scalability is an advantage as shown in FIG. 2 with 300, 400 and 1000 Ton CDC presses 31, 33 and 5 and much higher tonnages of several thousand tons with minimal press sizes, unlike the traditional low pressure powder metallurgy compaction presses. The unique suitability provides for high micro or nano powder consolidation to obtain much higher magnet and connected part densities, minimal grain growth, and composite multi-layered/functional gradient materials (FGM) fabrication and improved high performance properties of net shaping, superior surface finish, and improved mechanical/wear/corrosion/durability. Less or no post-machining or grinding is needed. Varied magnet sizes and compressions are provided with scalability to higher capacity CDC press sizes, automation and rapid fabrication.
Tables 1-9 and FIG. 1 through FIG. 28 provide the key results of the CDC higher pressure compacted samples and their unique properties such as geometrical, physical, and significant improvement in the magnetic properties as compared to the typical properties obtained so far.
Table 1a provides an extensive spectrum of potential applications of permanent magnets in several types of electric motors including brushless motors, magnetic resonance imaging, holding devices, power meters, transducers, magnetic couplings, magnetic separators, transport systems, and host of aerospace, automotive, and other commercial applications. Soft magnet and composites are useful for applications such as solenoids, relays, motors, generators, transformers, magnetic shielding etc. Table 1b provides select representative magnetic properties of permanent materials of various alloys and the bonded NdFeB alloys reveal Br of 9 kG, Hci of 9 kOe and BHmax of 9.5 MG Oe.
CDC compacted magnets using sintered magnetic powders are obtained without any additional bonding resins.
We have compacted successfully metals, ceramics, and composites including macro, micro and nano materials including variety of magnetic materials, bonded Nd—Fe-B magnets, soft Fe—Ni/Nano SiO2 nano composite magnets, SmCo magnets and SmCo with nano Fe. Table 2 provides an overview of both soft and permanent magnetic samples fabricated by CDC higher pressure compaction. FIG. 4a indicates the higher as-pressed green densities 50 of the CDC higher pressure compacted magnets with relatively minimal spring back %. Spring back % is the change in green part dimension after pressing, with reference to the initial die cavity dimensions. FIG. 4b indicates the spring back % 51 for 0.5 inch diameter CDC magnet ring samples and FIG. 4c indicates the spring back % 53 for 0.5 inch diameter cylindrical magnet disk samples.
FIGS. 4d-4h show compacted samples 54-58 of different compositions and aspect ratios. FIG. 4d shows CDEC high pressure compacted sample #549 (FeNi—30% NiFe2O4) with an aspect ratio (part height/wall thickness) of 3.21. FIG. 4e shows sample #792 (FeCoSiO2 15% Fe) with an aspect ratio of 2.18. FIG. 4f shows sample #793 (FeNi(100 nm)/SiO2(3 nm) 15% Fe) with an aspect ratio of 1.99. FIG. 4g shows sample #794 (Fe/SiO2) with an aspect ratio of 1.53. FIG. 4h shows sample #795 (Fe/SiO2) with an aspect ratio of 1.82.
CDC has been used for compacted SmCo—Fe composite magnets. For samarium cobalt-containing Fe nanocomposites, low temperature compaction is needed to prevent decomposition of Sm—Co. The reported BHmax energy product for combustion driven compacted Sm—Co with Fe composite is, BHmax of 31.5 MGOe. Such improvement in magnetic property as compared to the properties obtained by other methods such as hot isostatic pressing (HIP) or plasma pressure compacting (P2C) validates not only the scientific breakthrough of the uniqueness of CDC higher pressure 150 tsi cold pressing of the difficult-to-consolidate nanocomposite powders to retain the higher magnet part densities without cracking the sample under optimized compaction process controls and also provides minimal thermal post-process requirements. The following CDC compacted magnetic materials have been evaluated for magnetic properties as shown in FIG. 6 by a CMU researcher, indicating the unique advantages of higher intrinsic coercive force, Hci force as well as higher BHmax for CDC compacted magnets.
Examples are:
(SmCo5)0.85 Fe0.15:P2C
(SmCo5)0.85 Fe0.15:CDC
(SmCo5)0.80 Fe0.20:HIP
T=300K
Conditions used for compaction using various methods include P2C: Plasma Pressure Compaction (73 MPa, 5 min. 600° C.); CDC: Combustion Driven Compaction (2000 MPa, 550 ms, “20° C.”, Utron, Inc.); HIP: Hot Isostatic Pressing (0.435 MPa, 5 min, 550° C.)
CDC compacted soft magnetic nanocomposites have proved advantageous. Results 60 shown in FIGS. 5a and 5b show permeability 61 of CDC compacted soft magnetic nanocomposites 63 of Fe—Ni alloy powder system with 3 nm layer silicon oxide reveal much better permeability and high Q factor 65 qualities including very low hysteresis losses 67. These unique soft magnetic properties result from CDC higher pressure compacted soft nanocomposite magnetic materials with unique higher part densities and minimal post-process annealing done at lower temperatures for high frequency applications up to 1 MHz.
FIG. 6 shows improved BHmax properties 69 of CDC higher pressured compacted high temperature permanent magnetic materials of SmCo/Fe composites (CMU Research Project Publication); CDC-Combustion drive compaction; P2C-plasma pressure compaction; HIP (hot isostatic pressing).
The desirable characteristics of soft magnetic materials include higher permeability, high saturation induction (Bs), low-hysteresis loss, low-eddy current loss in alternating flux applications, constant permeability at low field strengths and minimum change in permeability with temperature. The effects of impurities, crystallinity or amorphous nature of the materials all affect properties. Structure insensitive properties are saturation induction (Bs), resistivity and Tc (Curie temperature) and structure sensitive properties which are affected by impurities or alloying elements, residual strain, grain size, etc are permeability (μ), coercive force (Hc), hysteresis loss (Wh), residual induction (Br), and magnetic stability. Controlling structure sensitive properties is accomplished through proper manufacturing process of the alloy and alloy compositions and use of proper thermal processing treatment without affecting the magnetic properties.
Significant improvement of permeability and Q-factor result from the UTRON compacted CDC nanocomposite magnetic Fe—Ni with 3 nm SiO2 powders, with higher part densities of 5.81 to 6.15 g/cc compared to the properties of traditional CoNi-ferrite materials. FIG. 5b shows dynamic hysteresis loops of soft magnetic materials up to 1 MHz for FeNi/SiO2 with density of 5.81 g/cc of the same materials with small eddy current losses in the frequency ranges.
CDC higher pressure compacted bonded neo magnets have improved properties.
Table 3 provides the listing of several CDC higher pressure compacted bonded Neo magnetic alloys and compositions. This invention provides CDC higher pressure compaction of up to 150 tsi, with unique compositions of mechanically blended magnetic powders and suitable epoxy resins in various percentages. Varying higher densities is a function of controlling the unique epoxy resin % in both before and after CDC compaction with suitable thermal processing. Select CDC compacted MQLP-B samples 71, 73, 75 are shown in FIGS. 7-9. Thermal processing of CDC compacted bonded Neo magnets were carried out at relatively lower temperature ranges of 150-225 deg C. at controlled heating and cooling rates, and at controlled shorter thermal processing times for less than 1 hour.
Due to the higher as-pressed densities, such unique post-process thermal treatment was found to be beneficial in terms of cost-effectiveness. Also, the uniquely processed CDC bonded neo samples were evaluated for densities and magnetic properties and were found to have much higher density improvement and magnetic property improvements as compared to conventional bonded magnets. The unique CDC produced magnets also have much higher improvements in magnetic induction, intrinsic coercive force and BHmax product as shown in Table 6-8 and FIGS. 10-12.
FIG. 10 shows that higher CDC compaction pressure samples have overall better magnetic properties 77 and density than lower CDC compaction pressure samples. There is  ̃0.2 kOe Hci difference in between higher and lower CDC compaction pressure samples, and this has been verified by 2 sets of coil.
FIG. 11 shows magnetic properties of Utron's kinetic higher performance bonded neo magnets (HPM Series); 11b. Effects of CDC higher pressure compaction improve densification 78 with higher remnance (Br) 79. FIG. 11 provides the improved magnetic property data 77 for UTRON Kinetics's advanced higher performance series, called HPM series, bonded neo magnetic alloy compositions.
FIG. 12 shows selected magnetic properties 80 of CDC compacted bonded neo magnets.
We have also compacted and evaluated other higher density bonded magnets using proprietary NdFeB mixes with Magnaquench base powders MQPB and MQPB+ mixes with higher Br (7.7) and BHmax (11.5). Based on geometry needs, Utron can fabricate any shape, ring discs, rectangles, etc. FIG. 12 provides a summary of magnetic properties of select CDC compacted and thermally processed samples.
The CDC higher pressure compacted samples using higher performance magnet (HPM) alloy series developed at UTRON use base alloy magnetic powders provided by Magnaquench series powders with suitable added epoxy procured by Utron Kinetics team independently from another vendor. Resin % at UTRON Kinetics, revealed significant magnetic property improvements of Br (higher remnance or induction) and Hci (higher demagnetization field). The epoxy resin that we used was blended in varying percentages with the baseline powders provided by the magnet baseline powder supplier.
Out of several thermoset polymers such as epoxies, polyesters, polyimides, cyanate esters, and phenolics, epoxy resin in varying % was chosen to be added in the matrix due to their better compatibility with the NdFeB magnetic powders, better firmess in terms of mechanical strength and ductility, and added protection both during and after CDC pressing for intended magnet applications due to the pyrophoric nature of the magnetic baseline powders especially in the fine sizes. Conventional compression molded or injection molded bonded neo magnets typically have higher %, 1.5-2% for example of resins, which may vary depending on the powder supplier and end users of bonded neo magnets.
Based on the unique magnetic property improvement results, one of the suggested powder composition with 1% resin was recommended by the principal scientist to the baseline powder supplier to provide MQLP-B+ together with  ̃1% resin weight %, for use in CDC higher pressure compaction. Epoxy resins typically have curing temperatures of 350 deg F, maximum service temperatures of 350 deg F, tensile strength of 8-13 ksi, and elongation of 3-7%. In bonded neo magnets, the properties depend on the % of such epoxy resins.
CDC compacted net shape magnetic ring 81 and steel core 83 assembly is provided for use in brushless electric motor applications.
FIG. 13 shows a new single step pressed steel core 83 mounted magnet product fabricated in steps of filling a die with steel powder mixed with <1% resin inside a separator tube and filling the die outside of the separator tube with magnetic powder, followed by withdrawing the separator tube and CDC pressing the powders up to 150 tsi. Prior art separately forms a steel ring and a magnet ring and bonds them together. The new product and methods minimize the number of steps and avoids chemical contamination of bonding.
The manufacturing advantage of layered or functional gradient materials for the CDC higher pressure compacted and processed magnetic outer ring and steel core assembly is new for brushless electric motor applications. Table 9 lists the CDC as-compacted properties of several mechanical samples and other geometries for unique brushless electric motor applications. Much higher densities were determined in all of the samples. Preliminary mechanical durability properties also were much better as compared to mechanical durability of conventional bonded magnets. Another unique way of CDC compacted at 150 tsi and thermally processed assembly of magnetic outer ring and steel composite inner core as shown in FIG. 13 for electric motor applications. The thermally processed composite steel core has the hardness range of RB 65-68 and showed ultimate tensile strength levels of  ̃12627-13093 psi, yield strengths of 6402-5911 psi and 4.5-4.8% ductility at fracture. Baselines magnetic materials of CDC compacted bonded MQLP-B materials provide  ̃4000 psi strength levels. The results indicate that the core samples are almost three times stronger than the magnetic layers. Bonded magnet and steel cores have indicated fairly good bonding with no delamination etc.
Innovative tooling is conceived and developed for fabricating thin walled net shaped bonded magnet rings with high length to wall thickness aspect ratios and improved magnetic properties.
Popular magnet geometries including thick walled rings with lower aspect ratios are shown in FIG. 3b. At Utron, we have fabricated thick walled ring samples of magnetic materials with lower aspect ratios successfully. FIGS. 4b, 4d-4h provide the results of those thick walled ring geometries with lower aspect ratios (<<4).
Using conventional processing methods, there have always been fabrication challenges to fabricate thin walled magnetic geometries using bonded or sintered magnet powders with aspect ratios (ratio between height and sample wall thickness) of >5-6 or higher. Using conventional low compaction pressures, this method has been less successful due to difficulties to firmly hold and eject the low density as-pressed magnetic parts. Injection molding methods produce much lower density parts, typically 5.8 g/cc densities in MIM injection molded parts as compared to 6 g/cc in low pressure compression molding or pressing. Multi-steps were required, such as extrusion of a rod to make a tube, cutting the tube to the final length, post-process grinding to obtain net shape and surface quality, etc. We have successfully used our CDC high pressure 300-Ton compaction press for making net shape high density magnets. We have conceived unique innovative tooling described and shown in Table 10 and FIGS. 14-17, created the tooling layout 91 with a die cavity 93 and lubricated core rod 95 and hollowing cylinder punch 97, and procured the tooling, carried out various sequences of powder filling 101, powder pressing 103, and part ejection 105 shown in FIGS. 14-22 using rapid milliseconds pressing cycle time.
FIG. 14 shows powder fill position for thin walled magnet fabrication.
FIG. 15 shows a powder pressing position to fabricate the thin walled net shape CDC magnet.
FIG. 16 shows CDC high pressure copacted net shape magnet part ejection.
FIG. 17 shows a view of the die cavity with lubricated core rod installed in view of the tooling in the 300 ton CDC press.
FIG. 18 shows a view of die cavity with bonded neo powder already filled in the annular hollow region of the core rod covered by upper punch (hollow cylinder) in an assembled view of the 300 ton CDC press. This sequence is ready before CDC compaction at high pressures (up to 150 tsi).
FIG. 19 shows a view of the die cavity with bonded neo powder already filled in the annular hollow region on the core red covered by upper punch (hollow cylinder) as shown in the view of the 300 ton CDC press. This sequence is shown without the piston engagement from the CDC combustion.
FIG. 20 shows a view of the CDChigh pressure compacted bonded neo thin walled ring in the core rod after the die cavity is lowered just before part removal.
FIG. 21 shows a view of the CDC high pressure compacted bonded neo thin walled ring in the core rod just before part removal.
FIG. 22 shows a view of the CDC high pressure compacted bonded neo thin walled ring in the core ring rod after disengaging from the piston of the CDC combustion chamber just before part removal.
FIG. 23 shows CDC high pressure compaction loading profile for bonded neo thin walled ring ( ̃95 tsi).
FIG. 24c shows CDC high pressure compaction loading profile for bonded neo thin walled ring ( ̃140-150 tsi).
FIG. 25 shows a view of the CDC high pressure compacted bonded neo thin walled ring at 95 tsi after the part removal from the core rod ( ̃140-150 tsi).
FIG. 26 shows angular side views of the successful CDC high pressure compacted bonded neo thin walled ring sample with higher as-pressed green densities without any cracking after compacting at  ̃140-150 tsi after the parts are removed from the core rod.
FIG. 27 shows the top view of a successful CDC high pressure compacted bonded neo thin walled ring sample with higher as-pressed green densities without any cracking after compacting at  ̃140-150 tsi after the parts are removed from the core rod.
FIG. 28 shows successful reproducible CDChigh pressure compacted bonded NdFeB—alloy magnet-thin walled ring samples after the parts are removed from the core rod.
We have created continuous, smooth and controlled CDC loading cycles with precombustion load 111 and combustion load 113 shown in FIG. 23 and FIGS. 24a to 24c to fabricate new thin walled bonded magnet rings 115 with large aspect ratios shown in FIGS. 25 through 28. The successfully fabricated rings with excellent bonding and crack-free nature were reproduced several times to verify the reproducibility and consistent geometrical and physical properties described in Table 10 as shown in FIG. 28. We plan to continue to thermally process and evaluate the improved magnetic properties similar to what we have evaluated using the 0.5 inch diameter cylindrical disk samples. Such unique innovative manufacturing of thin walled and high aspect ratios is possible using CDC high pressure compaction method, and such manufacturing is flexible for scaling up to fabricate thin walled rings of various diameters and wall thicknesses. The invention uses suitable CDC compaction press to obtain the required higher compaction pressures based on the pressing area. This invention includes fabrication of thin walled bonded permanent magnetic rings using new magnetic alloys, compositions and composites as well as rings of other materials by suitable CDC compaction process control and parameters using this invention.
Additional thin walled net shape CDC bonded neo magnet rings in addition to what is reported in Table 10 were fabricated to assure the reproducibility of one of the innovative net shape manufacturing of thin walled (e.g., wall thickness of  ̃0.059 inches) rings and also evaluate the properties of statistically acceptable numbers of rings identified a CDC Bonded Neo Magnets 3091-3115.
The invention provides new compositions, products, processes and apparatus for forming permanent, semi-permanent and soft magnets.
Combustion driven compaction at high compaction pressures have been successfully used to fabricate a broad spectrum of soft magnets from FeNi, FeCo-based magnetic materials and permanent magnets from Nd—Fe—B based alloys, SmCo-based alloys, etc., including bonded neo magnetic alloys of various compositions.
The CDC compacted FeNi—SiO2 nanocomposite soft magnets have shown superior magnetic permeability and lower hysteresis losses. CDC compacted SmCo—Fe nanocomposite magnets have yielded far greater resistance to demagnetization, higher coercive force Hci and much higher BHmax product (31.5 MGOe) as compared to those made by other manufacturing methods such as plasma pressure compaction (P2C) and hot-isostatic pressing (HIP).
Bonded permanent magnets have been compacted with innovative varying composition mixes using baseline magnetic powders and a unique epoxy based resin, for example 3M Scotch Cast—265 electrical resin below 1% by weight, called High Performance Magnet Series. The HPMS mixes are subject to changes of baseline powders together with suitable 1% or less epoxy based resin to improve the Br and Hci together with higher BHmax properties and with improved magnetic properties.
Net shape magnetic outer ring/steel composite inner core assembly have been successful as one unit using CDC compaction at 150 tsi and thermally processed assembly for potential brushless electric motor applications. The thermally processed composite steel core has the hardness range of RB 65-68 and showed ultimate tensile strength levels of  ̃12627-13093 psi, yield strengths of 6402-5911 psi and 4.5-4.8% ductility at fracture. Baseline magnetic materials of CDC compacted bonded MQLP-B materials provide  ̃4000 psi strength levels. The results indicate that the core samples have proven almost three times stronger than the magnetic layers. Bonded steel core magnets have indicated fairly good bonding with no delamination.
Combustion driven high pressure compaction (up to 150 tsi and higher) technology has been successfully used to fabricate intricate thin walled (e.g., 0.059 inch wall thickness) higher density bonded permanent magnet ring geometries with much higher aspect ratios (e.g., Between 16.64 to 17.59 shown in Table 10) than attainable by conventional powder metallurgical compaction methods with typical ratios of 4-5 or less by using innovative tooling development and part fabrication in net shape. The produced parts have been reproduced several times for part consistency and reliable fabricability.
The higher densities for the new net shape thin walled bonded Neo magnetic rings have been reported to be far superior than densities attainable by metal injection molding (MIM), e.g. compression molding or powder pressing methods using conventional hydraulic or mechanical means of methods.







TABLE 1A







Broad Spectrum of Applications of Permanent Magnets [20]












Recom-






mended

Alternative 
Condition or reason favoring


Application
material
Primary reason for selection
material
selection of alternative material





Aircraft magnetos, military or 
SmCo
Maximum energy per unit volume
Cast Alnico5
Availability or cost restraint


civilian






Ahematcas
SmCo
Compactness and reliability
Ferrite Alnico
Where space is available for a larger






volume of material of lower magnetic






energy and cost


Magnetos for lawn mowers garden
Ferrite
Adequate magnetic energy at lower cost
Alnico NdFeB
Higher energy material is required


tractors and outboard engines

than Alnico




Small direct current motors
Bonded 
Shape favors fabrication; adequate
Bonded NdFeB 
Higher magnetic ercrgy is required



ferrite
magnetic energy at lower cost
Sintered ferrite



Large direct current motors
SmCo
Maximum energy per unit volume
NdFeB
Where lower cost is required, operating






temperature is low


Automotive direct current motors
Ferrite
Adequate magnetic energy at lower cost
Bonded
Higher magnetic energy and less weight




than alternate materials
NdFeB



Automotive cranking motors
Ferrite
Adequate magnetic energy at lower cost
Bonded 
Higher magnetic energy and less weight




than alternate materials
NdFeB



Voice coil motors (computers)
NdFeB
High energy
SmCo
Availability


Acoustic transducers
Finite
Low cost
NdFeB
Higher magnetic energy allows smaller






size and weight


Magnetic couplings (small gap)
Fertile
Adequate magnetic energy at lower cost
Bonded NdFeB
Higher torque is required


Magnetic couplings (large gap)
NdFeB
High energy
SmCo
High operating temperature


Transport systems
NdFeB
High Energy
SmCo
Availabibry


Separators
Ferrite
Adequate magnetic energy at lower cost
NdFeB
High megnetic energy required


Magnetic resonance imaging
NdFeB
High energy
Ferrite
Where space is available for a larger






volume of material of lower energy


Magnetic focusing systems
NdFeB
High energy
SmCo
High operating temperatures or low-






temperature coefficient is required


Synchronous hysteresis motors
Isotropic 
Shape favors fabrication from wrought
Cobalt steel
Availability



FeCrCo
material




Holding devices
Ferrite
Adequate magnetic erergy at low cost
Alnico
Where holding force versus temperature






must not vary over wide ranges


Ammeters and voltmeters
Alnico
Low temperature coefficient
Not available
. . . 


Watt-hour meters
Alnico 
Low temperature coefficient
Not available
. . . 



5 cr 6
















TABLE 1b







Typical Magnetic Properties of Various Permanent Magnet Materials Including


Bonded NdFeB type of magnets








































Perme-


















Required
ance
Average

















magnetizing
coef-
recoil


















Hc
Hd


(BH)on

Hd
field
ficient
perme-























kA · 

kA · 

Br
Bb
kJ · 
MG · 
Bd
kA · 

kA · 

at 
ability,

























Designation
m−1
Or
m−1
Or
T
kG
T
kG
m−1
Or
T
kG
m−1
Or
m−1
Or
(BH)
G/Or




























31⁄2 % Cr steel
5.3
66
. . .
. . .
0.95
9.5
. . .
. . .
2.3
0.29
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .


6% W steel
5.9
74
. . .
. . .
0.95
9.5
. . .
. . .
2.6
0.33










17% Co steel
14
170
. . .
. . .
0.95
9.5
. . .
. . .
5.2
0.65
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .


36% Co steel
19
240
. . .
. . .
0.975
9.75
. . .
. . .
7.4
0.93
. . .
. . .
. . .
. . .
. . .
. . .
. . .
. . .


Cast Alnico 1
35
440
36
455
0.71
7.1
1.05
10.5
11
1.4
0.45
4.5
24
305
160
2.0
14
6.8


Cast Alnico 2
44
550
46
580
0.725
7.25
1.09
10.9
13
1.6
0.45
4.5
28
350
200
2.5
12
6.4


Cast Alnico 3
38
470
39
485
0.70
7.0
1.00
10.0
11
1.4
0.43
4.3
26
320
200
2.5
63
6.5


Cast Alnico 4
58
730
62
770
0.535
5.35
0.86
8.6
10
1.3
0.30
3.0
34
420
280
3.5
8.0
4.1


Cast Alnico 5
50
620
50
625
1.25
12.5
1.35
13.5
42
5.23
1.02
10.2
42
525
240
3.0
18
4.3


Cast Alnico 5DG
52
650
52
655
1.29
12.9
1.40
14.0
49
6.1
1.05
10.5
46
580
280
3.5
17
4.0


Cast Alnico 5-7
58
730
59
735
1.32
13.2
1.40
14.0
59
7.4
1.15
11.5
51
640
280
3.5
17
3.8


Cast Alnico 6
60
750
. . .
. . .
1.05
10.5
1.30
13.0
30
3.7
0.71
7.1
42
525
320
4.0
13
5.3


Cast Alnico 7
84
1,050
. . .
. . .
0.857
8.57
0.945 
9.45
30
3.7
. . .
. . .
. . .
. . .
400
5.0
8.2
. . .


Cast Alnico 8
130
1,600
138
1,720
0.83
8.3
1.05
10.5
40
5.0
0.506
5.06
76
950
640
8.0
5.0
3.0


Cast Alnico 9
115
1,450
. . .
. . .
1.05
10.5
. . .
. . .
68
8.5
. . .
. . .
. . .
. . .
560
7.0
7.0
. . .


Cast Alnico 12
76
950
. . .
. . .
0.60
6.0
. . .
. . .
14
1.7
0.315
3.15
43
540
400
5.0
5.6
. . .


Sintered Alnico 2
42
525
44
545
0.67
6.7
1.10
11.0
12
1.5
0.43
4.3
28
345
200
2.5
12
6.4


Sintered Alnico 4
56
700
61
760
0.52
5.2
. . .
. . .
10
1.2
0.30
3.0
32
400
280
3.5
. . .
7.5


Sintered Alnico 5
48
600
48
605
1.04
10.4
1.205 
12.05
29
3.60
0.785
7.85
37
465
240
3.0
18
4.0


Sintered Alnico 6
61
760
63
790
0.88
8.8
1.15
11.5
22
2.75
0.55
5.5
40
500
320
4.0
12
4.5


Sintered Alnico 8
125
1,550
134
1,675
0.76
7.6
0.94
9.4
36
4.5
0.46
4.6
80
1,000
640
8.0
5.0
2.1


Cunife
44
550
44
555
0.54
5.4
0.59
5.9
12
1.5
0.40
4.0
26
325
200
2.5
12
3.7


Bonded ferrite A
155
1,940
. . .
. . .
0.214
2.14
. . .
. . .
8
1.0
0.116
1.16
. . .
. . .
960
12.0
1.3
1.1


Bonded ferrite B
92
1,150
. . .
. . .
0.14
1.4
. . .
. . .
3
0.4
. . .
. . .
. . .
. . .
640
8.0
1.2
1.1


Sintered ferrite 1
145
1,800
276
3,450
0.22
2.2
. . .
. . .
8
1.0
0.11
1.1
72
900
800
10.0
1.2
1.2


Sintered ferrite 2
175
2,200
185
2,300
0.38
3.8
. . .
. . .
27
3.4
0.185
1.85
132
1,650
800
10.0
1.1
1.1


Sintered ferrite 3
240
3,000
292
3,650
0.32
3.2
. . .
. . .
20
2.5
0.16
1.6
130
1,600
800
10.0
1.1
1.1


Sintered ferrite 4
175
2,200
185
2,300
0.40
4.0
. . .
. . .
30
3.7
0.215
2.15
135
1,700
960
12.0
1.2
1.05


Sintered ferrite 5
250
3,150
287
3,590
0.355
3.55
. . .
. . .
24
3.0
0.173
1.73
138
1,730
1,200
15.0
1.0
1.05


NdFeB (sintered)
848
10,600
>1,350
>17,000
1.16
11.6
. . .
. . .
255
32
0.60
6.0
425
5,300
>2,000
>25.0
1.13
. . .


Bonded NdFeB
430
5,400
720
9,000
0.69
6.9
. . .
. . .
76
9.5
0.315
3.15
240
3,000
. . .
. . .
1.05
. . .


Hot-pressed NdFeB
560
7,000
1,280
16,000
0.80
8.0
. . .
. . .
110
13.7
0.38
3.8
295
3,700
. . .
. . .
1.05
. . .


Hot-formed NdFeB
880
11,000
1,20
15,000
1.20
12.0
. . .
. . .
274
34.2
0.59
5.9
465
5,800
. . .
. . .
1.05
. . .


Platinum cobalt
355
4,450
430
5,400
0.645
6.45
. . .
. . .
74
9.2
0.35
3.5
215
2,700
1,600
20.0
1.2
1.2


Cobalt rare earth 1
720
9,000
1,600
20,000
0.92
9.2
0.98
9.8
170
21
. . .
. . .
. . .
. . .
2,400
30.0
. . .
. . .


Cobalt rare earth 2
640
8,000
>2,000
>25,000
0.86
8.6
. . .
. . .
145
18
0.44
4.4
330
4,100
2,400
30.0
. . .
1.05


Cobalt rare earth 3
535
6,700
>1,200
>15,000
0.80
8.0
. . .
. . .
120
15
0.40
4.0
295
3,700
2,400
30.0
. . .
1.1


Cobalt rare earth 4
640
8,000
>640
>8,000
1.13
11.3
. . .
. . .
240
30
0.60
6.0
400
5,000
>1,600
>20.0
1.2
. . .





For nominal compositions, see Table 1: for mechanical and physical properties, see Table 3













TABLE 2







CDC Higher Pressure Compacted Permanent Magnets





























Spring
Spring













back 
back 













from
from
Aspect


Sam-


Peak
Green
Die




die; 
die 
Ratio


ple


Load
Density
Geo-
ID
OD
Height
Mass
ID
OD
(ht. /


#:
Date:
Description:
(tsi)
(g/cm3)
metry
(in)
(in)
(in)
(g)
(%)
(%)
wall)






















51
Jul. 5, 2001
Nd—Fe—B
154.0
6.0031
Tensile


0.3148
30.968





52
Jul. 6, 2001
Fe—Co—V
152.0
6.8090
Tensile


0.2856
31.867





55
Jul. 9, 2001
Nd—Fe—B + Cu 5%
159.0
6.1507
Tensile


0.3083
31.074





56
Jul. 9, 2001
Fe—Co—V + Cu 5%
151.0
6.9397
Tensile


0.2803
31.876





57
Jul. 9, 2001
Fe—Co—V
149.0
6.7797
Tensile


0.2873
31.919





84
Jul. 24, 2001
Nd—Fe—B + .5%ZnSt
152.0
5.9700
Tensile


0.3173
31.042





85
Jul. 25, 2001
Fe—Co—V + .5%ZnSt
151.0
6.8160
Tensile


0.2851
31.844





86
Jul. 26, 2001
Nd—Fe—B
168.0
5.8578
1/2′′ Cyl

0.5030
0.6400
12.208

0.60



87
Jul. 26, 2001
Nd—Fe—B
218.9
6.0607
1/2′′ Cyl

0.5040
0.6030
11.948

0.80



88
Jul. 26, 2001
Nd—Fe—B
218.9
6.1117
1/2′′ Cyl

0.5035
0.3070
6.122

0.70



89
Jul. 27, 2001
Fe—Co—V
208.8
6.8980
1/2′′ Cyl

0.5050
0.2760
6.249

1.00



154
Sep. 7, 2001
Magnequench MQU-F42
146.6
6.4106
1/2′′ Cyl

0.5050
0.5820
12.246

1.00



155
Sep. 12, 2001
Magnequench MQU-F42
146.6
6.4918
1/2′′ Cyl

0.5050
0.5750
12.252

1.00



156
Sep. 12, 2001
Magnequench MQU-F42
198.1
6.4733
1/2′′ Cyl

0.5030
0.5800
12.226

0.60



157
Sep. 13, 2001
Magnequench MQP-B
139.5
6.5188
1/2′′ Cyl

0.5040
0.5740
12.233

0.80



158
Sep. 13, 2001
Magnequench MQP-B
198.1
6.6678
1/2′′ Cyl

0.5040
0.5670
12.360

0.80



159
Sep. 13, 2001
Magnequench MQP-B
256.6
6.7441
1/2′′ Cyl

0.5040
0.5560
12.259

0.80



160
Sep. 14, 2001
Magnequench MQP-B
146.6
6.5501
1/2′′ Cyl

0.5050
0.5710
12.276

1.00



161
Sep. 14, 2001
Magnequench MQP-B
139.5
6.5206
1/2′′ Cyl

0.5035
0.2830
6.021

0.70



162
Sep. 18, 2001
Magnequench MQP-B 
139.5
6.3618
1/2′′ Cyl

0.5050
0.5900
12.320

1.00





(270 mesh)












163
Sep. 18, 2001
Magnequench MQP-B 
139.5
6.3307
1/2′′ Cyl

0.5050
0.6070
12.613

1.00





(270 mesh)












541
Jan. 6, 2003
FeNi 30% NiFe2O4
149.3
5.3570
Ring
0.3210
0.5050
0.2360
2.473
0.31
1.00
2.57


542
Jan. 6, 2003
FeCo1209 NiFe2O4
144.6

1/2′′ Cyl









543
Jan. 7, 2003
FeCo1209 SiO2
150.2
2.4840
1/2′′ Cyl

0.5040
0.1900
1.543

0.80



544
Jan. 7, 2003
FeCo1209 SiO2
146.6
2.4733
1/2′′ Cyl

0.5040
0.2440
1.973

0.80



549
Jan. 20, 2003
FeNi - 30% NiFe2O4
143.2

Ring










Jan. 20, 2003
FeNi - 30% NiFe2O4 
136.3

Ring











2nd shot













Jan. 20, 2003
FeNi - 30% NiFe2O4 
136.3
5.1503
Ring
0.3215
0.5040
0.2930
2.926
0.47
0.80
3.21




3rd shot












550
Jan. 21, 2003
FeNi - 30% NiFe2O4
149.3

Ring










Jan. 21, 2003
FeNi - 30% NiFe2O4 
133.7

Ring











2nd shot













Jan. 21, 2003
FeNi - 30% NiFe2O4 
136.3
5.1683
Ring
0.3215
0.5045
0.2370
2.383
0.47
0.90
2.59




3rd shot












551
Jan. 21, 2003
FeNi - SiO2
149.3

Ring










Jan. 21, 2003
FeNi - SiO2 2nd shot
130.3

Ring










Jan. 21, 2003
FeNi - SiO2 3rd shot
130.3
5.8077
Ring
0.3215
0.5040
0.2030
2.286
0.47
0.80
2.22


552
Jan. 21, 2003
FeCo1223 - SiO2
149.3

Ring










Jan. 21, 2003
FeCo1223 - SiO2 
133.7

Ring











2nd shot













Jan. 21, 2003
FeCo1223 - SiO2 
130.3
2.5773
Ring
0.3220
0.5045
0.2960
1.481
0.63
0.90
3.24




3rd shot












576
Apr. 30, 2003
SmCo5 + 15 wt% Fe 
141.1
7.0636
1/2′′ Cyl
0.5040
0.2900
6.697
0.80







(Sample2)












577
Apr. 30, 2003
SmCo5 + 15 wt% Fe 
144.8
7.1566
1/2′′ Cyl
0.5040
0.3350
7.838
0.80







(Sample1)












578
Jun. 11, 2003
FeCo—SiO2


Ring










Jun. 11, 2003
FeCo—SiO2 2nd shot


Ring









579
Jun. 11, 2003
Fe—Fe3O4


Ring










Jun. 11, 2003
Fe—Fe3O4 2nd shot

4.7328
Ring
0.3200
0.5100
0.2300
2.190
0.00
2.00
2.42


580
Jun. 11, 2003
FeNi—S1O2


Ring










Jun. 11, 2003
FeNi—S1O2

6.1455
Ring
0.3200
0.5000
0.1900
2.250
0.00
0.00
2.11


581
Jul. 1, 2003
Zeng 2 [Sm(CoFeCuZr)
168.0
6.9013
1/2′′ Cyl
0.5000
0.2200
5.050
0.00







7.5 + 20 wt%Fe]












582
Jul. 1, 2003
Alex [Pr7 Tb1 Fe87 
169.6
6.0913
1/2′′ Cyl
0.5000
0.3300
6.490
0.00







Nb0.5 Z0r.5 B4]












583
Jul. 1, 2003
Dilara [Fe50Cu50]
172.1
7.4932
1/2′′ Cyl
0.5000
0.2700
6.580
0.00





585
Jul. 3, 2003
s24 [SmCo5]
153.4
6.3796
1/2′′ Cyl
0.5000
0.1300
2.750
0.00





586
Jul. 3, 2003
sf24 [SmCo5 + 15 
153.5
6.2450
1/2′′ Cyl
0.5000
0.1500
2.940
0.00







atomic%Fe]












587
Jul. 3, 2003
s217f24 [Sm2Co17 + 
148.9
6.3159
1/2′′ Cyl
0.5000
0.1300
2.750
0.00







15 atomic%Fe]












736
Dec. 2, 2003
CMU #sm111403
166.8

1/2′′ Cyl











[Sm2Co17:Fe(20% 














atomic) (fine pwdr; 














size~few microns)]












737
Dec. 2, 2003
CMU #sm111803
163.5

1/2′′ Cyl











[Sm2Co17:Fe(20% 














atomic) (coarse pwdr; 














size~150 microns)]












738
Dec. 2, 2003
CMU #sm111903 
166.4

1/2′′ Cyl











[SmCo5]












753
Dec. 9, 2003
Uni of Del Sample #1
153.8
3.5779
Ring
0.3210
0.5040
0.2510
1.745
0.31
0.80
2.74




[FeCoSiO2Nov18d]












754
Dec. 9, 2003
Uni of Del Sample #2
156.9
5.4495
Ring
0.3210
0.5040
0.2750
2.912
0.31
0.80
3.01




[FeNi(100 nm)/S102]












755
Dec. 9, 2003
Uni of Del Sample #1
163.2

1/2′′ Cyl











[FeCoSiO2Nov18d]












756
Dec. 10, 2003
Uni of Del Sample #3
160.1
5.2700
1/2′′ Cyl
0.5040
0.1505
2.593
0.80







[FeNi(100 nm)/SiO2














(3nm)]












791
Feb. 5, 2004
Uni of Del Sample #1
166.1
3.5653
Ring
0.3330
0.5200
0.1910
1.398
4.06
4.00
2.04




[FeCoSiO2 10%Fe]












792
Feb. 5, 2004
Uni of Del Sample #3
166.7
3.7325
Ring
0.3250
0.5100
0.2020
1.499
1.56
2.00
2.18




[FeCoSiO2 15%Fe]












793
Feb. 5, 2004
Uni of Del Sample #4
166.9
5.6246
Ring
0.3230
0.5050
0.1815
1.980
0.94
1.00
1.99




[FeNi(100 nm)/SiO2














(3 nm) 15%Fe]












794
Feb. 23, 2004
Uni of Del Sample 
163.5
4.8468
Ring
0.3210
0.5025
0.1390
1.296
0.31
0.50
1.53




[Fe/SiO2]












795
Feb. 23, 2004
Uni of Del Sample 
162.9
5.6363
Ring
0.3210
0.5025
0.1650
1.789
0.31
0.50
1.82




[Fe/SiO2]












941
Aug. 26, 2004
CMU SMO811a
177.7

1/2′′ Cyl











[Sm2Co17 + 20 














atomic%Fe]












942
Aug. 26, 2004
CMU SMO811b
180.6

1/2′′ Cyl











[Sm2Co17 + 20 














atomic%Fe]












943
Aug. 26, 2004
CMU SMO811c
174.9

1/2′′ Cyl











[Sm2Co17 + 20 














atomic%Fe]
















TABLE 3







CDC Higher Pressure Compacted Bonded Neo-Magnets



























Change
Change












from
from












die
die






Green

ID/
OD/

Die
ID/
OD/
CDC


Sample
Date

Density
Mass:
width
length
Height
Geom-
width
length
Pressure


#:
Pressed
Description:
(g/cm3)
(g)
(in)
(in)
(in)
etry:
(%)
(%)
(tsi)





















2650
Dec. 14, 2009
MPQ-B
6.3415
13.988

0.5780
0.5130
.575 cyl

0.52
90.9


2651
Dec. 14, 2009
MQLP-B (-80M)
6.1889
14.030

0.5820
0.5200
.575 cyl

1.22
88.1


2652
Dec. 14, 2009
MQLP-B (-80M)
6.4342
13.997

0.5820
0.4990
.575 cyl

1.22
142.4


2653
Dec. 14, 2009
MPQ-B
6.6094
14.022

0.5800
0.4900
.575 cyl

0.87
141.8


2654
Dec. 14, 2009
MQLP-B (-80M)
6.4295
14.030

0.5800
0.5040
.575 cyl

0.87
141.8


2655
Dec. 14, 2009
MQLP-B (-80M)
6.4297
14.051

0.5810
0.5030
.575 cyl

1.04
135.6


2656
Dec. 14, 2009
MQLP-B (-80M)
6.4177
14.073

0.5820
0.5030
.575 cyl

1.22
137.7


2657
Dec. 14, 2009
MQLP-B (-80M)
6.1326
14.073

0.5850
0.5210
.575 cyl

1.74
65.4


2658
Dec. 15, 2009
MQLP-B (-80M)
6.1234
14.025

0.5850
0.5200
.575 cyl

1.74
83.8


2659
Dec. 15, 2009
MQLP-B (-80M)
6.1479
14.033

0.5840
0.5200
.575 cyl

1.57
79.5


2660
Dec. 15, 2009
MQLP-B (-80M)
6.1462
14.002

0.5840
0.5190
.575 cyl

1.57
70.9


2661
Dec. 15, 2009
MQLP-B (-80M)
6.1728
13.998

0.5835
0.5175
.575 cyl

1.48
79.5


2662
Dec. 15, 2009
MQLP-B (-80M)
6.1607
14.014

0.5830
0.5200
.575 cyl

1.39
83.1


2663
Dec. 15, 2009
MQLP-B (-80M)
6.1761
13.995

0.5830
0.5180
.575 cyl

1.39
70.9


2664
Dec. 15, 2009
MQLP-B (-80M)
6.3813
14.125

0.5830
0.5060
.575 cyl

1.39
149.9


2665
Dec. 15, 2009
MQLP-B (-80M)
6.3904
14.121

0.5825
0.5060
.575 cyl

1.30
149.5


2666
Dec. 15, 2009
MQLP-B (-80M)
6.3885
14.155

0.5830
0.5065
.575 cyl

1.39
142.4


2667
Dec. 15, 2009
MQLP-B (-80M)
6.3805
14.113

0.5825
0.5065
.575 cyl

1.30
119.5


2668
Dec. 15, 2009
MIOLP-B (-80M)
6.4117
14.126

0.5825
0.5045
.575 cyl

1.30
158.6


2669
Dec. 15, 2009
MQLP-B (-80M)
6.3731
14.159

0.5835
0.5070
.575 cyl

1.48
126.5


2670
Dec. 15, 2009
MQLP-B (-80M)
6.3898
14.116

0.5830
0.5050
.575 cyl

1.39
136.3


2671
Dec. 15, 2009
MQLP-B (-80M)
6.4017
14.118

0.5825
0.5050
.575 cyl

1.30
139.7


2672
Dec. 16, 2009
MQLP-B (-80M)
6.1210
14.028

0.5835
0.5230
.575 cyl

1.48
70.2


2673
Dec. 16, 2009
MQLP-B (-80M)
6.1611
14.015

0.5830
0.5200
.575 cyl

1.39
72.7


2674
Dec. 16, 2009
MQLP-B (-80M)
6.1485
14.040

0.5830
0.5220
.575 cyl

1.39
80.2


2675
Dec. 16, 2009
MQLP-B (-80M)
6.1845
14.035

0.5840
0.5170
.575 cyl

1.57
89.1


2676
Dec. 16, 2009
MQLP-B (-80M)
6.3849
25.216
0.3470
3.5520
0.2410
Tensile
1.17
0.65
82.6


2677
Dec. 16, 2009
MQLP-B (-80M)
6.5492
26.616
0.3470
3.5520
0.2480
Tensile
1.17
0.65
130.9


2678
Dec. 16, 2009
MPQ-B
6.8440
27.029
0.3470
3.5530
0.2410
Tensile
1.17
0.68
155.4


2821
Jan. 27, 2010
CDC-H PM1-2
6.4643
13.986

0.5810
0.4980
.575 cyl

1.04
152.4


2822
Jan. 27, 2010
CDC-HPM1-1
6.4961
14.083

0.5810
0.4990
.575 cyl

1.04
138.6


2823
Jan. 27, 2010
CDC-H PM1-3
6.3671
13.997

0.5810
0.5060
.575 cyl

1.04
143.8


2824
Jan. 27, 2010
CDC-HPM1-4
6.3049
14.052

0.5810
0.5130
.575 cyl

1.04
155.2


2825
Jan. 27, 2010
C DC-H PM1-5
6.0069
14.223

0.5810
0.5450
.575 cyl

1.04
160.4


2826
Jan. 27, 2010
CDC-HPM1-6
6.6381
14.107

0.5805
0.4900
.575 cyl

0.96
11.8


2827
Jan. 28, 2010
CDC-HPM1-1
6.5296
14.014

0.5810
0.4940
.575 cyl

1.04
145.6


2828
Jan. 28, 2010
CDC-HPM1-1
6.3949
14.086

0.5810
0.5070
.575 cyl

1.04
137.4


2829
Jan. 28, 2010
CDC-HPM2-1
6.4586
14.100

0.5810
0.5025
.575 cyl

1.04
136.5


2830
Jan. 28, 2010
CDC-HPM2-1
6.5786
14.062

0.5810
0.4920
.575 cyl

1.04
127.2


2831
Jan. 28, 2010
CDC-HPM1-2
6.4224
14.021

0.5810
0.5025
.575 cyl

1.04
150.2


2832
Jan. 28, 2010
CDC-H PM1-3
6.4086
13.977

0.5810
0.5020
.575 cyl

1.04
147.9


2833
Jan. 28, 2010
CDC-HPM1-4
6.3322
14.113

0.5810
0.5130
.575 cyl

1.04
143.1


2834
Jan. 29, 2010
CDC-HPM1-5
6.1349
14.073

0.5810
0.5280
.575 cyl

1.04
157.4


2835
Jan. 29, 2010
CDC-HPM2-1
6.5074
14.037

0.5810
0.4965
.575 cyl

1.04
150.2


2836
Jan. 29, 2010
CDC-HPM2-1
6.7173
27.079
0.3465
3.5525
0.2460
Tensile
1.02
0.67
137.8


2837
Jan. 29, 2010
CDC-H PM1-1
6.6591
27.099
0.3480
3.5520 
0.2483
Tensile
1.46
0.65
145.7


2838
Jan. 29, 2010
CDC-H PM1-2
6.6345
27.017
0.3480
3.5520 
0.2485
Tensile
1.46
0.65
144.1


2839
Jan. 29, 2010
CDC-H P M1-3 
6.5023 
26.976
0.3480 
3.5520 
0.2532 
Tensile
1.46
0.65
144.1


2840
Feb. 1, 2010
CDC-H PM1-4
6.4460
26.971
0.3475
3.5510
0.2553
Tensile
1.31
0.62
160.6


2841
Feb. 1, 2010
CDC-H PM1-4
6.1894
26.844
0.3475
3.5500
0.2647
Tensile
1.31
0.60
149.0


2842
Feb. 1, 2010
CDC-HPM3-1
6.5927
27.009
0.3485
3.5530
0.2500
Tensile
1.60
0.68
148.8


2843
Feb. 1, 2010
CDC-HPM3-2
6.5556
27.018
0.3480
3.5500
0.2515
Tensile
1.46
0.60
139.2


2844
Feb. 2, 2010
CDC-HPM3-3
6.4709
27.199
0.3480
3.5510
0.2565
Tensile
1.46
0.62
152.9


2845
Feb. 2, 2010
CDC-HPM3-4
6.4483
27.069
0.3480
3.5520
0.2562
Tensile
1.46
0.65
144.1


2846
Feb. 2, 2010
CDC-HPM3-5
6.2205
26.792
0.3480
3.5520
0.2628
Tensile
1.46
0.65
144.3


2847
Feb. 2, 2010
CDC-HPM3-6
6.6580
26.949
0.3485
3.5530
0.2470
Tensile
1.60
0.68
138.7


2848
Feb. 2, 2010

6.4931
14.000

0.5800 
0.4980
.575 cyl

0.87
148.6


2849
Feb. 2, 2010
CDC-HPM3-1
6.4335
13.983

0.5800
0.5020
.575 cyl

0.87
135.4


2850
Feb. 3, 2010
CDC-HPM3-2
6.4560
14.032

0.5800
0.5020
.575 cyl

0.87
170.4


2851
Feb. 3, 2010
CDC-HPM3-3
6.3228
13.934

0.5800
0.5090
.575 cyl

0.87
161.8


2852
Feb. 3, 2010
CDC-HPM3-4
6.2814
13.734

0.5800
0.5050
.575 cyl

0.87
153.4


2853
Feb. 3, 2010
CDC-HPM3-5
6.1521
13.984

0.5800
0.5250
.575 cyl

0.87
162.4


2917
Mar. 5, 2010
MQP-B
6.2008
3.940
0.3200 
0.5020 
0.3300 
1/2′′ Ring
0.00
0.40
145.1


2918
Mar. 5, 2010
MQP-B
6.1935
3.995
0.3200 
0.5020 
0.3350 
1/2′′ Ring
0.00
0.40
150.2


2920
Mar. 5, 2010
MQP-B
6.2198 
2.000
0.3200 
0.5020 
0.1670 
1/2′′ Ring
0.00
0.40
155.8


2921
Mar. 5, 2010
MQP-B2
6.2028
3.995
0.3200
0.5020
0.3345
1/2′′ Ring
0.00
0.40
142.5


2922
Mar. 5, 2010
MQP-B2
6.1308
3.990
0.3200
0.5020
0.3380
1/2′′ Ring
0.00
0.40
142.5


2931
Mar. 9, 2010
MQP-B
6.6629 
14.020

0.5800 
0.4860
.575 cyl

0.87
148.4


2932
Mar. 9, 2010
MQP-B
6.6206 
14.017

0.5800 
0.4890
.575 cyl

0.87
145.9


2933
Mar. 9, 2010
MQP-B
6.6290 
14.006

0.5800 
0.4880
.575 cyl

0.87
148.8


2934
Mar. 9, 2010
MQP-B
6.6167 
14.023

0.5800 
0.4895
.575 cyl

0.87
141.1


2935
Mar. 10, 2010
MQP-B
6.6468 
14.015

0.5800 
0.4870
.575 cyl

0.87
154.9


2936
Mar. 10, 2010
MQP-B
6.6419 
14.019

0.5800 
0.4875 
.575 cyl

0.87
154.9


2937
Mar. 10, 2010
MQP-B2
6.6212
14.004

0.5800
0.4885
.575 cyl

0.87
155.8


2938
Mar. 10, 2010
MQP-B2
6.6206
14.017

0.5800
0.4890
.575 cyl

0.87
150.6


2939
Mar. 10, 2010
MOP-B2
6.6057
14.014

0.5800
0.4900
.575 cyl

0.87
154.5


2940
Mar. 10, 2010
MQP-B2
6.6126
14.000

0.5800
0.4890
.575 cyl

0.87
154.7


2941
Mar. 10, 2010
MQP-B2
6.6014
14.005

0.5800
0.4900
.575 cyl

0.87
154.5


2942
Mar. 10, 2010
MQP-B
6.5894
14.008

0.5800 
0.4910
.575 cyl

0.87
155.4
















TABLE 4







CDC Compacted Magnetic Sample Data in the As-Pressed Condition






















Change










from 





Cured




die
CDC


Sample

Density
Mass:
OD
Height
Fill
OD
Compaction


#:
Description:
(g/cm3)
(g)
(in)
(in)
Ratio
(%)
Pressure


















2656
MQLP-B
6.4177
14.073
0.5820
0.5030
(1.9 vib)
1.22
High


2664
MQLP-B
6.3813
14.125
0.5830
0.5060
(1.9 vib)
1.39
High


2665
MQLP-B
6.3904
14.121
0.5825
0.5060
(1.9 vib)
1.30
High


2666
MQLP-B
6.3885
14.155
0.5830
0.5065
(1.9 vib)
1.39
High


2672
MQLP-B
6.1210
14.028
0.5835
0.5230
(1.8 vib)
1.48
Low


2673
MQLP-B
6.1611
14.015
0.5830
0.5200
(1.9 vib)
1.39
Low


2674
MQLP-B
6.1485
14.040
0.5830
0.5220
(1.9 vib)
1.39
Low


2675
MQLP-B
6.1845
14.035
0.5840
0.5170
(1.9 vib)
1.57
Low





Die Geometry; 0.575′′ OD Cylinder die













TABLE 5







CDC Compacted and Thermally Cured Samples






















Change
Change










from 
from






Cured



die
green
Change
CDC


Sample

Density
Mass:
OD
Height
OD
height
in mass
Compaction


#:
Description:
(g/cm3)
(g)
(in)
(in)
(%)
(%)
(g)
Pressure



















2656
MQLP-B
6.3851
14.078
0.5830
0.5040
1.39
0.20
0.0046
High


2664
MQLP-B
6.3842
14.132
0.5830
0.5060
1.39
0.00
0.0065
High


2665
MQLP-B
6.3700
14.128
0.5830
0.5070
1.39
0.20
0.0069
High


2666
MQLP-B
6.3594
14.160
0.5830
0.5090
1.39
0.49
0.0050
High


2672
MQLP-B
6.1015
14.037
0.5835
0.5250
1.48
0.38
0.0088
Low


2673
MQLP-B
6.1279
14.028
0.5840
0.5215
1.57
0.29
0.0127
Low


2674
MQLP-B
6.1113
14.046
0.5835
0.5245
1.48
0.48
0.0060
Low


2675
MQLP-B
6.1350
14.049
0.5855
0.5190
1.83
0.39
0.0135
Low
















TABLE 6







Select Properties of Higher Density Bonded Neo Magnets












Density
Br
HcJ
(8H)max


CDC Sample
(g/cc)
(kG)
(kOe)
(MGOe)





CDC-2666-MQLP-B
6.36 
7.51 
9.1 
11.6


CDC-2669-MQLP-B
6.349
7.314
9.116
10.9
















TABLE 7







UTRON Kinetics Combustion Driven Compaction (CDC) on MOLP-B

















Coil 38468















OD
Height
Mass
Density
Br
Hci
(BH) max



(cm)
(cm)
(g)
(g/cc)
(kG)
(kOe)
(MGOe)





CDC Low Load 2672
1.482
1.334
14.037
6.10
7.14
8.9
10.3


CDC Low Load 2673
1.483
1.325
14.028
6.13
7.14
8.9
10.4


CDC Low Load 2674
1.482
1.332
14.046
6.11
7.12
9.0
10.4


CDC Low Load 2675
1.487
1.318
14.049
6.14
7.15
8.9
10.4


CDC Low Load
1.484
1.327
14.040
6.12
7.14
8.9
10.4


CDC High Load 2656
1.481
1.280
14.078
6.39
7.50
9.1
11.5


CDC High Load 2664
1.481
1.285
14.132
6.38
7.51
9.1
11.6


CDC High Load 2665
1.481
1.288
14.128
6.37
7.52
9.2
11.6


CDC High Load 2666
1.481
1.293
14.160
6.36
7.51
9.1
11.6


CDC High Load
1.481
1.287
14.125
6.37
7.51
9.1
11.6
















TABLE 8







UTRON Kinetics Combustion Driven Compaction (CDC) Samples


















Coil 35038
Helmholtz Coil

















OD
Height
Mass
Density
Br
Hci
(BH) max

Bdi ~ 


Sample ID
(cm)
(cm)
(g)
(g/cc)
(kG)
(kOe)
(MGOe)
MMT
PC3





CDC #2830 HPM (2-1)
1.480
1.259
14.078
6.51
7.69
9.0
11.6
2.535
7.19


CDC #2831 HPM (1-2)
1.476
1.279
14.022
6.41
7.50
9.1
11.6
2.557
7.17


CDC #2832 HPM (1-3)
1.477
1.280
13.979
6.37
7.38
9.0
11.2
2.545
7.12


CDC #2833 HPM (1-4)
1.477
1.312
14.111
6.28
7.36
9.0
11.1
2.563
7.00


CDC #2834 HPM (1-5)
1.474
1.351
14.072
6.10
7.08
9.0
10.4
2.536
6.74


CDC #2835 HPM (2-1)
1.474
1.256
14.047
6.55
7.73
9.0
11.6
2.511
7.18


CDC #2848 HPM (3-6)
1.476
1.256
14.044
6.54
7.69
9.3
11.0
2.508
7.16


CDC #2849 HPM (3-1)
1.474
1.281
13.982
6.39
7.57
9.3
11.6
2.557
7.17


CDC #2850 HPM (3-2)
1.477
1.270
14.033
6.45
7.63
9.3
11.7
2.565
7.23


CDC #2851 HPM (3-3)
1.474
1.303
13.920
6.26
7.38
9.4
11.3
2.556
7.05


CDC #2852 HPM (3-4)
1.477
1.278
13.728
6.27
7.41
9.4
11.4
2.523
7.07


CDC #2853 HPM (3-5)
1.474
1.342
13.977
6.10
7.14
9.4
10.6
2.549
6.82
















TABLE 9







As-High Pressure CDC Compacted (@ 150 tsi) Properties of Core Steel (Base


Material*) Mechanical Test Samples with varying additive levels, and Trial Hollow Slug (with


inner core steel with some additive and outer magnetic ring (Pressed together as one unit).

























Change
Change











from die
from die





Green

ID/
OD/


ID/
OD/



Sample

Density
Mass:
width
length
Height
Die
width
length
Load


#:
Description:
(g/cm3)
(g)
(in)
(in)
(in)
Geometry:
(%)
(%)
(tsi)




















2782
MQLP-B //1000C Pure Iron- layered
7.3950
29.811
0.3480
3.5420
0.2460
Tensile
1.46
0.37
157.4


2783
Base material*
7.6044
31.008
0.3455
3.5325
0.2488
Tensile
0.73
0.10
153.6


2784
Base material + medium additive
7.2039
31.008
0.3465
3.5380
0.2627
Tensile
1.02
0.26
142.5


2785
Base material + medium additive
7.2193
31.015
0.3460
3.5360
0.2622
Tensile
0.87
0.20
149.8


2786
Base material + medium additive
7.3108
30.989
0.3450
3.5380
0.2587
Tensile
0.58
0.26
142.3


2787
Base material + low additive
7.4810
30.975
0.3445
3.5350
0.2527
Tensile
0.44
0.17
151.8


2788
Base material + low additive
7.4762
30.996
0.3450
3.5375
0.2530
Tensile
0.58
0.24
141.8


2789
Base material + low additive
7.4723
32.000
0.3450
3.5375
0.2613
Tensile
0.58
0.24
148.9


2790
Base material + high additive
7.0953
29.998
0.3460
3.5400
0.2580
Tensile
0.87
0.31
142.1


2791
Base material + high additive
7.0433
30.009
0.3470
3.5400
0.2600
Tensile
1.17
0.31
146.2


2792
Base material + high additive
7.1263
29.993
0.3460
3.5390
0.2568
Tensile
0.87
0.28
143.0


W81
Base material + 
6.8597
141.964
0.4750
1.3662
0.9800
1.35 Cyl
0.00
1.20
135.4



low additive//MQLP-B

























TABLE 10







As-Pressed CDC Higher Pressure Compacted Net Shape Formed Thin Walled 


Bonded Neo Rings (300 Ton CDC Press)

























Aspect









Change
Change
Ratio



Green





from die
from die
(Height/


Sample
Density
Mass:
ID*
OD*
Wall
Height
ID
OD
Wall


#:
(g/cm3)
(g)
(in)
(in)
Thickness
(in)
(%)
(%)
Thick)



















3083*
5.9652
23.716
1.2020
1.3200
0.059
1.0380
0.38
0.59
17.59


3084
6.1217
23.947
1.2030
1.3210
0.059
1.0205
0.47
0.66
17.30


3085
6.2934
23.933
1.2040
1.3218
0.0589
0.9935
0.55
0.72
16.87


3087
6.2630
23.986
1.2040
1.3213
0.05865 
1.0050
0.55
0.68
17.14


3088
6.2634
23.966
1.2030
1.3213
0.05915 
0.9960
0.47
0.68
16.85


3089
6.2703
23.973
1.2033
1.3215
0.0591
0.9950
0.49
0.70
16.83


3090
6.2401
23.987
1.2030
1.3220
0.0595
0.9940
0.47
0.74
16.71


3107
6.2951
24.009
1.2035
1.3223
0.0594
0.9880
0.51
0.76
16.64





*#3083-CDC compacted Thin Walled Ring sample (MQLP-B powder with 1% Resin) at 95 tsi


# 3084- CDC compacted Thin Walled Ring sample (MQEP-B+powder with 1% Resin) at ~150 tsi


All the other Thin Walled Ring samples (#3085 to #3107) were done ~140-150 tsi range using MQLP-B Powder with 1% Resin


Average measurements were taken for Internal Diameter (ID) and Outer Diameter (OD) dimensions.


Note:


**The CDC higher pressure compacted samples using Higher Performance Magnet (HPM Alloy Series Developed at UTRON Using Base Alloy Mixes with Suitable Epoxy Resin % at UTRON Kinetics, revealed significant magnetic property improvements of Br (higher remnance or induction) and Hci (higher intrinsic coercive force, and as required to reduce the magnetic induction to zero). This epoxy resin we used was blended in varying percentages with the baseline powders provided by the magnet baseline powder supplier.


Based on the unique magnetic property improvement results, one of the suggested powder composition with 1% resin was recommended by the Principal Scientist to the baseline powder supplier to provide MQLP-B+together with ~1% resin weight%, to demonstrate the proof of concept using CDC higher pressure compaction. Epoxy resins typically have curing temperatures of 350 degF; Max service Temp of 350 degF; Tensile Strength of 8-13 ksi, Elongation of 3-7% and in bonded neo magnets , the properties depend on the % of such epoxy resins.


**Additional rings were fabricated to assure the reproducibility of one of the innovative net shape manufacturing of thin walled (e.g., wall thickness of ~0.059 inches) rings and also evaluate the properties of statistically acceptable #of rings; CDC Bonded Neo Magnet Sample # 3091-3115 as of filing this provisional patent application.






While the invention has been described with reference to specific embodiments, modifications and variations of the invention may be constructed without departing from the scope of the invention, which is defined in the following claims.

## Claims

1. Composition comprising a compact thin walled rare earth magnet made of a composite powder and 1% by weight of epoxy resin precompressed at about 20 tons per square inch and compressed at 150 tons per square inch to a density greater than or equal to 6.1 grams/cm3 and heat treated to a curing temperature of the resin, wherein the composite powder comprises a samarium—cobalt alloy powder, wherein powder comprises about 85-95% by weight 4,4′-Isopropylidenediphenol-epichlorohydrin polymer and about 1-10% by weight cyanoguanidine.

2. The composition of claim 1, wherein the magnet is coated with zinc, nickel or gold plating.

3. The composition of claim 1, wherein the magnet has a ring shape and has a length to wall thickness aspect ratio of about 16.7 or more and a density of about 6.10 g/cm3 or more.