A new method for producing neodymium magnets that takes dysprosium-saving to the extreme
Since they were commercialized in 1983, neodymium magnets (sintered neodymium-iron-boron magnet, TDK product name: NEOREC) have maintained their position as the most powerful type of magnet known to industry. Demand for these magnets continues to grow in many fields, for example actuators that drive magnetic heads on hard disk drives, motors used in industrial equipment and energy-saving appliances, and more recently in the drive motors used in HEVs and EVs. Neodymium magnets are made of two rare earth elements, Nd (neodymium), and Dy (dysprosium) -- which is particularly scarce and expensive; to increase a magnet’s coercive force TDK has newly developed its HAL (High-Anisotropy field Layer) production process which achieves dramatic reductions in the amount of Dy used, and still improves magnetic properties. We have succeeded in improving the performance of these magnets by optimally diffusing minimum amounts of Dy into substrates consisting of neodymium magnets that are among the best in the world.