Life Cycle Assessment of Rare Earth Elements-Free Permanent Magnet Alternatives: Sintered Ferrite and Mn-Al-C.

Permanent magnets are fundamental constituents in key sectors such as energy and transport, but also robotics, automatization, medicine, etc. High-performance magnets are based on rare earth elements (RE), included in the European list of critical raw materials list. The volatility of their market increased the research over the past decade to develop RE-free magnets to fill the large performance/cost gap existing between ferrites and RE-based magnets. The improvement of hard ferrites and Mn-Al-C permanent magnets plays into this important technological role in the near future. The possible substitution advantage was widely discussed in the literature considering both magnetic properties and economic aspects. To evaluate further sustainability aspects, the present paper gives a life cycle assessment quantifying the environmental gain resulting from the production of RE-free magnets based on traditional hexaferrite and Mn-Al-C. The analysis quantified an advantage of both magnets that overcomes the 95% in all the considered impact categories (such as climate change, ozone depletion, human toxicity) compared to RE-based technologies. The benefit also includes the health and safety of working time aspects, proving possible reduction of worker risks by 3-12 times. The results represent the fundamentals for the development of green magnets that are able to significantly contribute to an effective sustainable transition.

Superparamagnetic-blocked state transition under alternating magnetic fields: towards determining the magnetic anisotropy in magnetic suspensions.

The potential of magnetic nanoparticles for acting as efficient catalysts, imaging tracers or heating mediators relays on their superparamagnetic behaviour under alternating magnetic fields. In spite of the relevance of this magnetic phenomenon, the identification of specific fingerprints to unequivocally assign superparamagnetic behaviour to nanomaterials is still lacking. Herein, we report on novel experimental and theoretical evidences related to the superparamagnetism observed in magnetic iron oxide nanoparticle suspensions at room temperature. AC magnetization measurements in a broad field frequency range from mHz to kHz and field intensities up to 40 kA m-1 unambiguously demonstrate the transition from superparamagnetic to blocked states at room temperature. Our experimental observations are supported by a theoretical model based on the stochastic Landau-Liftshitz-Gilbert equation. An empirical expression is proposed to determine the effective magnetic anisotropy from the field frequency value beyond which AC magnetization shows hysteretic behaviour. Our results significantly improve the understanding and description of the superparamagnetism of iron oxide nanoparticles, paving the way towards a more efficient exploitation of their unique magnetic properties.

An extraordinary chiral exchange-bias phenomenon: engineering the sign of the bias field in orthogonal bilayers by a magnetically switchable response mechanism.

Isothermal tuning of both the magnitude and the sign of the bias field has been achieved by exploiting a new phenomenon in a system consisting of two orthogonally coupled films: SmCo5 (out-of-plane anisotropy)-CoFeB (in-plane anisotropy). This has been achieved by using the large dipolar magnetic field of the SmCo5 layer resulting in the pinning of one of the branches of the hysteresis loop (either the ascending or the descending branch) at a fixed field value while the second one is modulated along the field axis by varying the orientation of an externally applied magnetic field. This means the possibility of controlling the sign of the bias field in a manner not reported to date. Moreover, modulation of the bias field strength is possible by varying the thickness of a spacer between the SmCo5 and CoFeB layers. This study shows that the observed phenomena find their origin in the competition between the artificially induced anisotropies in both layers, resulting in a reversible chiral bias effect that allows the selection of the initial sign of the bias field by switching (upwards/downwards) the magnetization in the SmCo5 film.

Evidence of anomalous switching of the in-plane magnetic easy axis with temperature in Fe3O4 film on SrTiO3:Nb by v-MOKE and ferromagnetic resonance.

The evolution of the magnetic anisotropy directions has been studied in a magnetite (Fe3O4) thin film grown by infrared pulsed-laser deposition on SrTiO3(100):Nb substrate. The magnetic easy axes at room temperature are found along the in-plane 〈100〉 film directions, which means a rotation of the easy axis by 45° with respect to the directions typically reported for bulk magnetite and films grown on single-crystal substrates. Moreover, when undergoing the Verwey transition temperature, TV, the easy axis orientation evolves to the 〈110〉 film directions. This anomalous behavior has been demonstrated by measuring first the angular dependence of coercivity and remanence well above and below TV by high-resolution vectorial magneto-optical Kerr effect (v-MOKE). Ferromagnetic resonance (FMR) measurements have additionally proven a well-defined fourfold magnetic anisotropy induced during growth with confirmed easy axis directions along 〈100〉 for T > TV and 〈110〉 for T < TV. These results provide a clear proof of the possibility of tuning magnetic anisotropy in Fe3O4 thin films by proper control on the growth parameters and substrate choice.

Development of permanent magnet MnAlC/polymer composites and flexible filament for bonding and 3D-printing technologies.

Searching for high-performance permanent magnets components with no limitation in shape and dimensions is highly desired to overcome the present design and manufacturing restrictions, which affect the efficiency of the final devices in energy, automotive and aerospace sectors. Advanced 3D-printing of composite materials and related technologies is an incipient route to achieve functional structures avoiding the limitations of traditional manufacturing. Gas-atomized MnAlC particles combined with polymer have been used in this work for fabricating scalable rare earth-free permanent magnet composites and extruded flexible filaments with continuous length exceeding 10 m. Solution casting has been used to synthesize homogeneous composites with tuned particles content, made of a polyethylene (PE) matrix embedding quasi-spherical particles of the ferromagnetic τ-MnAlC phase. A maximum filling factor of 86.5 and 72.3% has been obtained for the composite and the filament after extrusion, respectively. The magnetic measurements reveal no deterioration of the properties of the MnAlC particles after the composite synthesis and filament extrusion. The produced MnAlC/PE materials will serve as precursors for an efficient and scalable design and fabrication of end-products by different processing techniques (polymerized cold-compacted magnets and 3D-printing, respectively) in view of technological applications (from micro electromechanical systems to energy and transport applications).

Emergence of the Stoner-Wohlfarth astroid in thin films at dynamic regime.

The Stoner-Wohlfarth (SW) model is the simplest model that describes adequately the magnetization reversal of nanoscale systems that are small enough to contain single magnetic domains. However for larger sizes where multi-domain effects are present, e.g., in thin films, this simple macrospin approximation fails and the experimental critical curve, referred as SW astroid, is far from its predictions. Here we show that this discrepancy could vanish also in extended system. We present a detailed angular-dependent study of magnetization reversal dynamics of a thin film with well-defined uniaxial magnetic anisotropy, performed over 9 decades of applied field sweep rate (dH/dt). The angular-dependent properties display a gradual transition from domain wall pinning and motion-like behaviour to a nucleative single-particle one, as dH/dt increases. Remarkably, in the high dynamic regime, where nucleation of reversed domains is the dominant mechanism of the magnetization reversal (nucleative regime), the magnetic properties including the astroid become closer to the ones predicted by SW model. The results also show why the SW model can successfully describe other extended systems that present nucleative regime, even in quasi-static conditions.

Note: Vectorial-magneto optical Kerr effect technique combined with variable temperature and full angular range all in a single setup.

Here, we report on a versatile full angular resolved/broad temperature range/vectorial magneto optical Kerr effect (MOKE) magnetometer, named TRISTAN. Its versatility relies on its capacity to probe temperature and angular dependencies of magnetization reversal processes without the need to do any intervention on the apparatus during measurements. The setup is a combination of a vectorial MOKE bench and a cryostat with optical access. The cryostat has a motorized rotatable sample holder with azimuthal correction. It allows for simultaneous and quantitative acquisition of the two in-plane magnetization components during the hysteresis loop at different temperatures from 4 K up to 500 K and in the whole angular range, without neither changing magnet orientation nor opening the cryostat. Measurements performed in a model system with competing collinear biaxial and uniaxial contributions are presented to illustrate its capabilities.