Neodymium magnets are the strongest magnet ever found on the earth. These are rare earth magnets and offer a wide range of applications in different areas. Neodymium magnet is formed using powder based metallurgical procedures. This magnet possesses mechanical properties that appear more like a ceramic. The nature of neodymium magnets is hard and brittle. In this article we are going to see how magnets are made.
Procedure of manufacturing neodymium magnet
The procedure of making this magnet involves a series of steps. All these steps might vary depending on the kind and application of magnet to be produced.
Acquiring essential ingredients and elements
This is the first step, which marks the beginning of magnet making process. In this step you are required to collect all the desired ingredients and alloys such as neodymium, iron, and boron that are required to make neodymium magnets.
Melting and Milling
This is the second step in the preparation of neodymium magnet. After you have all the required ingredients move to the next step melting. In this step, all the ingredients are melted with the application of electric currents to make ingots. Now milling is performed by grounding the ingots to form a fine powder. The quantity of alloys and the mixture used determines the strength, grade, and other qualities of the magnet.
Pressing the magnet and aligning it
After the above step you are left with the powdered form of these mixed alloys. Now, this powdered form is pressed to obtain a solid state. A shape is given to the ingredients followed by magnetization process through application of a magnetic field. Pressing of a magnet can be performed in a variety of ways. Once the magnet is pressed in a block shape, it is sintered to provide precise magnetic properties.
Though pressing helps in giving a solid block shape to the magnet, but the magnet is still semi solid and is solidified with the help of sintering method. Sintering aids in locking and keeping the magnetic particles in place through the application of heat. In sintering process, the amount of heat applied is high enough to adhere but low enough to prevent its liquefaction.
Sintering is often found to reduce the size of the magnets. Magnets are required to be in particular shapes and sizes as desired by the area of their application. So another procedure known as machining is done to refine the results.
As neodymium has a tendency to corrode. So to save the magnet from corrosion, magnets are coated on uniform basis. E.g. Plastic coated magnets to protect against corrosion.
In this process, you get a charged and solid shape magnet. In addition, the magnet is assigned pole directions. To activate the magnetic power an industrial magnetizer is used. The slugs of the magnet are kept into the magnetizer and exposed to a highly strong magnetic field.
This is an intricate process of creating a permanent magnet. All these steps are performed under the supervision of experts.