The Production and Technology of Permanent Magnet Rods

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Permanent magnet rods are essential components in various industrial applications, from filtering magnetic particles in liquids and powders to ensuring the efficiency of electrical machines. The production of these powerful magnets involves a complex series of processes and technologies that are crucial to their performance and durability. Ningbo Yongshengcheng Magnetic Technology Co., Ltd. is a permanent magnet rod manufacturer. This article will explore the intricacies of the production process and the technological advancements that have shaped the manufacturing of permanent magnet rods.

Permanent Magnet Rods

Permanent magnet rods, also known as magnetic sticks, are cylindrical magnets made from strong permanent magnet materials such as neodymium (NdFeB) or samarium cobalt (SmCo). These materials are chosen for their ability to generate high magnetic fields on their surface, which are vital for attracting ferrous contaminants from products as they flow around the rod.

Production Process of Permanent Magnet Rods

The manufacturing process of permanent magnet rods begins with the selection of the appropriate magnetic material. Materials like AISI 304 Modified are used, which have been engineered to control the stability of austenite by decreasing Ni, C, N content. This modification allows for the generation of transformation-induced martensite at room temperature, a key property for the magnetic scaling rod.

The process typically involves several key steps:

1. Alloy Preparation: RE-3d transition metal alloys are produced on an industrial scale by vacuum induction melting. Inert gas is backfilled to the vacuumed chamber before melting, and the alloys are commonly ingot cast.

2. Powder Production: The material may require a size reduction stage prior to final milling. For example, after vacuum melting and casting, the Sm-Co alloy is crushed in a high-energy hammer mill to a particle size range of less than 500 μm.

3. Particle Alignment and Pressing: The fine ferrite particles are mixed with water and placed in a magnetic field to improve alignment and density. Polyvinyl alcohol and camphor can be used as binders during compression, which are removed during the sintering stage.

4. Sintering and Heat Treatment: The ferrite magnet sintering process is carried out at high temperatures, and the addition of materials like SiO2 may facilitate densification without grain growth by liquid-phase sintering.

5. Machining: Sintered ferrites are hard and brittle, so they are typically cut with a saw and ground with diamond tools to the specified dimensions.

6. Magnetizing: The final step of making a ferrite magnet is to magnetize it with a high field, which is 2.5–3 times higher than the coercivity of the material.

Technological Advancements

Recent developments in the manufacturing processes for permanent magnets include the use of laser beams for the magnetic scaling rod, which replaced mechanical notches and allowed for the development of a scaling rod that satisfies both accuracy and intensity. However, due to the high cost and time consumption of laser irradiation, new manufacturing processes with plastic forming have been developed to improve productivity.

Additive manufacturing (AM) is another area of growth, enabling the production of complex, near-net-shape parts with minimal loss of material. This approach is particularly attractive for rare-earth permanent magnets, as it allows for the production of complex shapes that are often cost-prohibitive to machine from brittle permanent magnet materials.

The production of permanent magnet rods is a testament to the advancement of materials science and manufacturing technology. From the careful selection of materials to the intricate processes of sintering and magnetizing, each step is crucial in creating a product that is both effective and reliable. As technology continues to evolve, we can expect further improvements in the efficiency and capabilities of permanent magnet rods, ensuring their continued importance in a wide range of industrial applications.

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Ningbo Yongshengcheng Magnetic Technology Co., Ltd.

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