Grant: Alliance Grants

Rare earth (RE) permanent magnets, particularly neodymium-iron-boron (NdFeB) magnets, are critical for many green and digital technologies, including electric vehicles, wind power, sensors, and consumer electronics. With the transition of Canada's economy from fossil fuels to renewable energy, the demand for RE permanent magnets is expected to increase rapidly in Canada. The Canadian manufacturing sector heavily relies on overseas supplies of rare earth elements and its supply chain is under significant risk due to increasing demands for RE permanent magnets and emerging trade tensions. Our collaborative team will develop new recycling, powder synthesis, manufacturing, and post-processing processes to fabricate permanent magnet components using recycled magnets. Our team aims to achieve the following objectives: (1) develop angular powders using RE waste magnets, with an emphasis on adopting and optimizing the hydrogen decrepitation and jet milling processes; (2) develop an inductively coupled plasma process to fabricate spherical NdFeB powder using angular powder; (3) employ powder metallurgy and additive manufacturing methods to fabricate new RE magnet products; (4) optimize post-processing treatments to improve magnetic properties with target magnetic performance higher than 90% of the original magnet. This project will support the development of a domestic circular supply chain for RE metals. By recycling RE metals from end-of-life magnets, the outcome of this project will support a steady, domestic source of RE magnets to related industries while reducing waste and environmental impact. The addition of recycled RE magnets to the market will reduce the overall cost of electric vehicles, wind power, and other green energy technologies as well as support supply chain security. The project will train 21 highly qualified personnel to support the Canadian Critical Minerals Strategy and its long-term plans, from recycling to re-manufacturing.