How to Manufacture Magnet?
A magnet is a substance that can exert a perceptible force on other materials without actually coming into touch with them. The force in question is known as a magnetic force. Depending on the circumstances, it may either attract or repel. Even though all known materials produce some magnetic force, that force is often rather weak in most materials, making it difficult to detect. The magnetic force that other materials collectively referred to as magnets is far greater. The planet itself acts as a gigantic magnet.
Magnetic metals have been around for millennia, and the science behind them is being used in a variety of sectors throughout the globe. The manufacturing process might be difficult, but it is necessary to generate magnetic material. If not outsourced to experienced magnet producers, producing a few pounds of material might take weeks, cost millions, and require specialized equipment. ROBO magnetic provides solutions for producing both cost-effective and efficient magnets for all your magnet applications. Let’s have a look at the many processes that are used to manufacture magnets.
Different Methods of Manufacturing Magnets
The production of magnets may be done in an extremely wide variety of ways. They come in a wide variety of forms, including but not limited to the following:
Sintering (Rare-earths, Ferrites, and Alnicos)
Magnets made from rare-earth elements (such as neodymium magnets), ferrite, and Alnico may all be produced using this approach. Sintering is a technique that first compacts tiny particles at high pressure in a magnetic field that is aligned, then sintering to fuse the powders into a solid form. Because the magnet’s form is rough after the sintering process, it must be machined to obtain the desired tight tolerances. There is a limit to the complexity of the forms that can be pressed using this method.
Pressing (Rare-earths)
In addition to sintering, other methods for producing rare-earth magnets include die pressing (in which pressure is applied in just one direction) and isostatic pressing (in which equal pressure is applied in all directions). Depending on preference, die-pressed magnets may have an aligning magnetic field that is either parallel to or perpendicular to the pressing direction. When magnets are pressed, the aligning field should run perpendicular to the pressing direction. This results in magnets with superior magnetic characteristics than those produced by parallel pressing. Pressed magnets with isostatic pressure can attain superior magnetic characteristics compared to die-pressed magnets.
Injection Molding or Pressure Bonding (Rare Earths and Ferrites)
Magnets made of rare earth elements or ferrite may be produced using either injection molding or pressure bonding to incorporate the magnet powders into the carrier matrix. The density of magnet materials produced in this manner is lower than that of magnet materials produced by pure sintering, resulting in lower magnet characteristics. On the other hand, magnets that have been bonded or injection molded may be machined into rather complicated designs while maintaining near tolerances.
How Are Magnets Manufactured?
Regardless of your purchase, the magnet production process, which includes several phases to guarantee our clients get the highest quality magnets available, takes around 4-6 weeks from beginning to end. We are professionals at every procedure stage, from mining to your application.
Stage 1: Mining
The first step in the production of rare earth magnets is the mining of raw materials.
Stage 2: Strip Casting
A quick processing method called strip casting involves pouring molten material into bigger green sand or shell molds. The shell begins to mold and burns as the molten metal cools, and by the time the magnet is completely solid, the shell has almost completely broken down.
Stage 3: HDDR (Hydrogenation Disproportionation Desorption Recombination)
The HDDR (hydrogenation disproportionation desorption recombination) technique may turn NdFeB-type sintered magnets with compositions into bonded magnets.
Stage 4: Milling
The liquid alloy will be broken down and ground into small particles once it has been poured and cooled with water.
Stage 5: Pressed
The ultra-fine powder will next be pushed into a mold while the mold is also subjected to magnetic energy. This is accomplished by using a coil of wire that acts as a magnet when electrical current is sent through it. Magnetism is locked in when the mixture is squeezed.
Stage 6: Sintering
After the powder has been compressed, it may be sintered at over 1200°C in a furnace with a hydrogen environment. All the crushed particles are fused during this process to create a single magnet.
Stage 7: Performance Evaluation
A magnet’s strength is affected by several measures in various ways, such as its pulling force and magnetic field strength. Each of these characteristics will need to be evaluated and quantified.
Stage 8: Machining
The raw magnets are machined into the necessary form at this step; however, a diamond-plated cutting tool is needed owing to the strength of certain magnets.
Stage 9: Surface Treatment
Because certain magnets are prone to breaking and chipping, they must be coated, cleaned, dried, and plated as the last step before remagnetizing. Our magnets may be coated with different metals, PTFE, or even rubber in addition to the nickel-copper-nickel alloy that is most often used.
Stage 10: Magnetised
After being plated, the final material is remagnetized, putting it within a coil that generates a magnetic field three times higher than the magnet’s needed strength.
Stage 11: Packing
The last part of the procedure involves our team of specialists carefully selecting and packaging the magnets correctly so they can be delivered securely and get our clients in excellent shape to be utilized in many situations and applications worldwide.
Where Can I Buy Bulk Neodymium Magnets?
With a 16-year history and annual sales of over 800 tons of finished neodymium magnets, ROBO Magnetic is one of China’s main neodymium magnet manufacturers.
ROBO Magnetic prioritizes client satisfaction and product excellence. We can provide a report on the manufacturing component approval, and all of our products have ISO 9001:2015 certification.
We are an international company that provides services to customers in the industrial, commercial, and retail sectors all over the world. Get in touch with us to learn more about how we can provide you with superior neodymium magnets.
Magnet Manufacturing Requires a Substantial Capital Investment
Large expenditures in capital equipment are needed for these procedures. For instance, only to create magnet blocks, it is necessary to use hydrogen decrepitation equipment, vacuum strip casters, jet milling equipment, cold isostatic presses, magnetic orienting presses, and sintering and annealing furnaces. These are all significant expenses. To help you access cost-effective magnet manufacturing solutions, ROBO magnetic is here to offer you the best services.
The magnet blocks are cut, machined, and ground using accurate tools. When the pieces go through the machining and grinding procedures, a significant amount of value is added since the magnet material is created using a powder metallurgy process along with many other processes.
Cutting is well planned. To reduce kerf losses, wire cutting is performed using very thin wire. When required, grinding is utilized, but it is carefully designed to minimize material losses.
To manufacture high-quality goods in an affordable and ecologically sustainable manner, electroplating and other coating activities require substantial expenditure.
The Future
Researchers are still looking for magnets that are even more potent than the ones already in use. The creation of compact, high-torque electric motors for laptop disk drives and industrial robots driven by batteries is one use for stronger permanent magnets. High-speed trains might be propelled and levitated utilizing more powerful electromagnets and pulsed magnetic fields. A central, magnetic “rail” would sustain and direct these trains, also known as maglev trains. They would move without touching the rail, reducing mechanical noise and friction. In addition, satellites might be launched into orbit using pulsed magnetic fields instead of expensive and cumbersome booster rockets.
Additional novel materials and procedures might be developed using stronger magnets as research instruments. In nuclear fusion research, hot, reactive nuclear plasma that would normally melt any solid material vessel is being contained by strong, pulsed magnet fields. The behavior of semiconductors in electronics may be studied using magnetic fields in materials research to ascertain the consequences of fabricating micro-sized integrated circuits.
Conclusion
Magnets, amongst other physical objects, have powerful magnetic fields. ROBO Magnetic consolidates all you need to manufacture your Neodymium Magnet manufacturing processes from start to finish efficiently and successfully.
With more than 16 years of expertise, we can provide a variety of magnet production options to guarantee the safe delivery of your magnets. We safeguard your privacy and sensitive data with the best security methods and guidelines. To satisfy your unique needs, we can deliver the magnet items wherever you choose in a timely, affordable, and cost-effective manner. Please get in touch with us or get a quote if you need further details.
