Grant: Alliance Grants

The proposed project aims to develop a sustainable alternative to rare-earth metals used in electric vehicle permanent magnets by focusing on a promising rare-earth-free candidate known as tetrataenite L10-FeNi phase. To circumvent the impossible kinetic requirements imposed by natural tetrataenite formation in meteorites through ultraslow cooling after millions of years, this project pioneers a strategic combination of alloy engineering, modern metallurgy, and thermomechanical treatments to replicate this structure in cast FeNi alloys. Our approach seeks to overcome the diffusion constraint with an out-of-the-box approach by investigating the viability of modifying the atomic arrangement, optimizing the material texture, generating mechanical driving forces, and strategic application of heat treatment. Developed in collaboration with Dana Incorporated, an industry leader in automotive electrification, the project ensures that the resulting manufacturing scheme is not only scientifically robust but also practical, scalable and aligned with Canada's Critical Mineral Strategy.Focused on the 'downstream' segment of the critical minerals' value chain, this initiative also aligns with Canada's net-zero greenhouse gas emissions target by 2050. By capitalizing on Canada's significant nickel production, especially in Manitoba and Ontario, the project supports domestic circular economy and mitigates risks related to geopolitical uncertainties affecting rare-earth metals. The project is a tripartite collaboration between the University of New Brunswick, Dana Incorporated, and CanmetMATERIALS, Natural Resources Canada (CMAT). Dana's expertise in automotive electrification ensures rapid commercialization, while CMAT will facilitate a seamless transition from research to production lines of metal manufacturers. By developing rare-earth-free permanent magnets, this project aims to enhance Canada's EV manufacturing capabilities, promote sustainability, and fulfill national environmental goals. This project aligns with the program's emphasis on technologies supporting domestic value chains and advancing commercial readiness.