Higher density melt spun RE-Fe-B isotropic magnets

Traditional techniques for consolidating melt spun RE-Fe-B powders tend to incur significant volumes of non-magnetic material, like porosity and the polymer binder. Several alternative consolidation techniques are being studied in an effort to reduce this non-magnetic component and improve the performance of these magnets. Rapid Electric Discharge Sintering (REDS) is one such technique that offers a novel way to fully densify melt spun RE-Fe-B with fast cycle times and minimal material wastage. This study highlights the initial development stages of REDS formed magnets and outlines the technical and economic challenges facing such novel technologies.