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Exploration of Alnico Permanent Magnet Microstructure And Iowa State University Capstones, Theses and Graduate Theses and Dissertations Dissertations 2018 Exploration of Alnico permanent magnet microstructure and processing for near final shape magnets with solid-state grain alignment for improved properties Aaron Gregory Kassen Iowa State University Follow this and additional works at: https://lib.dr.iastate.edu/etd Part of the Materials Science and Engineering Commons, and the Mechanics of Materials Commons Recommended Citation Kassen, Aaron Gregory, "Exploration of Alnico permanent magnet microstructure and processing for near final shape magnets with solid-state grain alignment for improved properties" (2018). Graduate Theses and Dissertations. 16390. https://lib.dr.iastate.edu/etd/16390 This Dissertation is brought to you for free and open access by the Iowa State University Capstones, Theses and Dissertations at Iowa State University Digital Repository. It has been accepted for inclusion in Graduate Theses and Dissertations by an authorized administrator of Iowa State University Digital Repository. For more information, please contact [email protected]. Exploration of Alnico permanent magnet microstructure and processing for near final shape magnets with solid-state grain alignment for improved properties by Aaron Gregory Kassen A dissertation submitted to the graduate faculty in partial fulfillment of the requirements for the degree of DOCTOR OF PHILOSOPHY Major: Materials Science & Engineering Program of Study Committee: Iver E. Anderson, Major Professor Scott Chumbley David C. Jiles Matthew J. Kramer Alan M. Russell The student author, whose presentation of the scholarship herein was approved by the program of study committee, is solely responsible for the content of this dissertation. The Graduate College will ensure this dissertation is globally accessible and will not permit alterations after a degree is conferred. Iowa State University Ames, Iowa 2018 Copyright © Aaron Gregory Kassen, 2018. All rights reserved. ii DEDICATION Seldom is it possible to surround oneself with such superior individuals who dedicate their time and patience during the pursuit of something as daunting as a person’s Ph.D. I have found myself surrounded by such people, and in that way, my gratitude is endless as it made the process achievable. I consider myself charmed. Creating a list of people responsible for seeing you through a process so daunting as a Ph.D. would be endless, and as long as the very document I now sit to write. It begins during our undergraduate studies, with the professors who instill a healthy curiosity, and sound method as foundational principles and continues with graduate studies as you struggle for a full understanding that comes only from the experience and knowledge transferred by those relationships. So, understand this dedication is not meant to be exhaustive, but rather a survey of the land. Inhabited by, people such as my wife Sarah who had no idea what she was getting into when she married me and my family who were an endless fount of encouragement, close acquaintances, and dear friends who in the end put up with so much. Every Ph.D. student must surround themselves with family and friends to finish the process. That support structure is what keeps us all going when the results are not what we had hoped and helps celebrate the infrequent successes we are blessed with over these few years. I have had such a structure in my time at the Ames Laboratory and Iowa State University, where the staff was always encouraging, reliable, approachable, and friendly. I found it in my Powder Group compatriots, the individuals who I now count as part of my extended family, who were there from day one. Finally, Dr. Iver Anderson, who kept my eyes on the goal, and kept me optimistic about things even when I was not. I made it, but I suspect you always knew I would. Science is magic that works... -Kurt Vonnegut, Cat’s Cradle, 1963 iii TABLE OF CONTENTS Page ACKNOWLEDGMENTS ................................................................................................. vi ABSTRACT ...................................................................................................................... vii CHAPTER I: GENERAL INTRODUCTION: CURRENT TECHNOLOGIES FOR PERMANENT MAGNET MOTORS .............................................................................................1 Motivations .........................................................................................................................1 Traction Drive Motor Technology ......................................................................................3 Permanent Magnet Selection ..............................................................................................5 Alnico Coercivity and Energy ..........................................................................................10 Processing Overview ........................................................................................................13 Thesis ................................................................................................................................15 CHAPTER II: COMPRESSION MOLDING OF HIGH-PRESSURE GAS ATOMIZED POWDERS TO FORM NEAR-NET SHAPE ALNICO-BASED PERMANENT MAGNETS ...19 Abstract .............................................................................................................................19 Introduction .......................................................................................................................20 Experimental Procedure ....................................................................................................23 Results and Discussion .....................................................................................................27 Conclusions .......................................................................................................................37 References .........................................................................................................................38 CHAPTER III: COMPRESSION MOLDING AND NOVEL SINTERING TREATMENTS FOR ALNICO TYPE-8 PERMANENT MAGNETS IN NEAR-FINAL SHAPE WITH PREFERRED ORIENTATION ............................................................................39 Abstract .............................................................................................................................39 Introduction .......................................................................................................................40 Experimental Procedure ....................................................................................................42 Results and Discussion ......................................................................................................43 Conclusions .......................................................................................................................48 References .........................................................................................................................48 iv CHAPTER IV: SOLID-STATE TEXTURE DEVELOPMENT IN SINTERED ALNICO-BASED PERMANENT MAGNETS FROM HIGH-PRESSURE GAS ATOMIZED POWDERS FOR TRACTION DRIVE TECHNOLOGY .......................................51 Abstract .............................................................................................................................51 Introduction .......................................................................................................................52 Experimental Procedure ....................................................................................................55 Results and Discussion ......................................................................................................57 Conclusions .......................................................................................................................61 References .........................................................................................................................62 CHAPTER V: NOVEL MECHANISMS FOR SOLID-STATE PROCESSING AND GRAIN GROWTH WITH MICROSTRUCTURE ALIGNMENT IN ALNICO-8 BASED PERMANENT MAGNETS .............................................................................................64 Abstract .............................................................................................................................64 Introduction .......................................................................................................................65 Experimental Procedure ....................................................................................................67 Results and Discussion ......................................................................................................69 Conclusions .......................................................................................................................72 References .........................................................................................................................73 CHAPTER VI: EXPLORATION OF THE ALNICO-8 COMPOSITION DEPENDENT PHASE EVOLUTION THROUGH X-RAY DIFFRACTION, MAGNETIC THERMOGRAVIMETRIC ANALYSIS, AND DIFFERENTIAL SCANNING CALORIMETRY ...........................................................................................................................75 Abstract .............................................................................................................................75 Introduction ........................................................................................................................76
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