Compression molding of anisotropic NdFeB bonded magnets in a polycarbonate matrix

Anisotropic bonded Nd2Fe14B (NdFeB) magnets in a polycarbonate (PC) binder matrix are fabricated using a compression molding process. The weight fractions (w.f.) of NdFeB in PC on the batch mixer are 20, 50, 75, 85 and 95% compared to the twin screw extruder with 20, 50 and 75% respectively. The density of the 95% batch mixed magnets fabricated was 5.34 g/cm(3) and the magnetic properties are, intrinsic coercivity H-ci, = 942.99 kA/m, remanence B-r = 0.86 T, and energy product (BH)(max) = 120.96 kJ/m(3). The measured tensile properties are in the range of 27-59 MPa, comparable to that of polyamide (PA), polyphenylene sulfide (PPS) bonded magnets and demonstrating potential for bonded magnet applications. Scanning electron microscopy showed that the onset of failure occurs in the magnetic particle- matrix interface. This study demonstrates that compression additive molding technique can be used to fabricate high performance NdFeB polycarbonate composite magnets with improved mechanical properties.