Magnet recycling to create Nd—Fe—B magnets with improved or restored magnetic performance

1. A method for manufacturing a recycled Nd—Fe—B permanent magnet comprising:

demagnetizing magnetic material from a waste magnet assembly by cyclic heating And cooling of the magnetic material, fragmenting adhesives attached to the magnetic material, cracking coating layers of the magnetic material, and subjecting the magnetic material to at least one of: a) a mechanical treatment or b) a chemical treatment, to remove the coating layers and prepare the magnetic material without impurities;

fragmenting the demagnetized magnetic material to form a powder;

mixing the powder with a) a rare earth material R that comprises between 0.1 to 1 at. % of the total mixture and b) an elemental additive A to produce a homogeneous powder, wherein the rare earth material R comprises at least one of: i) Nd or ii) Pr with a ratio of 75 wt. % Nd to 25 wt. % Pr, and the elemental additive A comprises at least one of: i) Dy, ii) Co, iii) Cu, iv) Fe; and

sintering and magnetizing the homogenous powder to form a recycled Nd—Fe—B magnetic product that comprises 1.98 at. % oxygen or less and has a remanence and a coercivity at least the same as a waste magnet part from the waste magnet assembly.

2. The method of claim 1 comprising performing the fragmenting and the mixing concurrently.

3. The method of claim 1 wherein fragmenting the demagnetized magnetic material comprises fragmenting the demagnetized magnetic material to an average particle size between 1 to 4 microns.

4. The method of claim 1 wherein fragmenting the demagnetized magnetic material to form the powder comprises removing particles with a particle fraction size bigger than an average size of particles in the demagnetized magnetic material from the demagnetized magnetic material to obtain 1.98 at. % oxygen or less in the demagnetized magnetic material.

5. The method of claim 4 wherein removing, from the demagnetized magnetic material, particles with the particle fraction size bigger than the average size of particles in the demagnetized magnetic material to obtain 1.98 at. % oxygen or less in the demagnetized magnetic material comprises removing particles in an inert atmosphere.

6. The method of claim 5 , wherein removing particles in an inert atmosphere comprises removing particles in argon.

7. The method of claim 4 wherein removing, from the demagnetized magnetic material, particles with the particle fraction size bigger than the average size of particles in the demagnetized magnetic material to obtain 1.98 at. % oxygen or less in the demagnetized magnetic material comprises sieving.

8. The method of claim 1 comprising:

mixing the homogenous powder with another element selected from the elemental additive A.

9. The method of claim 1 comprising:

harvesting the magnetic material from one or more magnet assemblies by:

separating a waste magnet part from a non-magnet part included in the magnet assemblies; and

extracting the waste magnet part from the non-magnet part, wherein the magnetic material comprises the waste magnet part.

10. The method of claim 1 wherein fragmenting the demagnetized magnetic material to form the powder comprises fragmenting the demagnetized magnetic material to form the powder with an average particle size between about 1 micron to about 2 millimeters, the method comprising:

further fragmenting the powder to an average particle size between about 1 to about 4 microns; and

homogenizing the powder.

11. The method of claim 10 wherein:

homogenizing the powder comprises homogenizing the powder that comprises an average particle size between about 1 micro to about 2 millimeters; and

mixing the powder with a) the rare earth material R that comprises between 0.1 to 1 at. % of the total mixture and b) the elemental additive A to produce the homogeneous powder comprises mixing the powder with an average particle size between about 1 to about 4 micros with a) the rare earth material R and b) the elemental additive A to produce the homogenous powder.

12. The method of claim 10 wherein:

mixing the powder with a) the rare earth material R that comprises between 0.1 to 1 at. % of the total mixture and b) the elemental additive A to produce the homogeneous powder comprises mixing the powder with an average particle size between about 1 micron to about 2 millimeters with a) the rare earth material R and b) the elemental additive A to produce the homogenous powder; and

homogenizing the powder comprises homogenizing the powder that comprises an average particle size between about 1 to about 4 microns.

13. The method of claim 1 comprising:

fragmenting the rare earth material R and the elemental additive A separately from fragmenting the demagnetized magnetic material to form the powder, wherein mixing the powder with a) the rare earth material R that comprises between 0.1 to 1 at. % of the total mixture and b) the elemental additive A to produce the homogeneous powder comprises mixing the powder with a) the fragmented rare earth material R and b) the fragmented elemental additive A to produce the homogeneous powder.

14. The method of claim 1 where sintering and magnetizing the homogenous powder to form a recycled Nd—Fe—B magnetic product comprises:

adding a lubricant to the homogenous powder;

compacting the homogenous powder to form a green compact;

sintering the green compact between about 1000° C. to about 1100° C.;

heat treating the sintered green compact between about 490° C. to about 950° C.; and

magnetizing the heat treated green compact to an inert atmosphere below 15° C. to form the recycled Nd—Fe—B magnetic product.

15. The method of claim 1 , wherein an atomic percentage of Co in the recycled Nd—Fe—B magnetic product is less than or equal to 3 at. %.

16. The method of claim 1 , wherein an atomic percentage of Cu in the recycled Nd—Fe—B magnetic product is less than or equal to 0.3 at. %.

17. The method of claim 1 , wherein a combined atomic percentage of Fe and Co in the recycled Nd—Fe—B magnetic product is less than or equal to 77 at. %.

18. The method of claim 1 , wherein a combined atomic percentage of Nd, Pr, and Dy in the recycled Nd—Fe—B magnetic product is greater than or equal to a combined atomic percentage of Nd, Pr, and Dy in a waste magnet part from the waste magnet assembly.

19. The method of claim 1 , wherein a combined atomic percentage of Nd, Dy, and Pr in the recycled Nd—Fe—B magnetic product is less than or equal to 18 at. %.

20. The method of claim 1 , wherein the coercivity of the recycled Nd—Fe—B magnetic product is between about 0 to about 20% greater than the coercivity of a waste magnet part from the waste magnet assembly.

21. The method of claim 1 , wherein:

mixing the powder with a) the rare earth material R that comprises between 0.1 to 1 at. % of the total mixture and b) the elemental additive A to produce the homogeneous powder comprises homogeneously distributing the rare earth material R and the elemental additive A within the demagnetized magnetic material; and

sintering and magnetizing the homogenous powder to form the recycled Nd—Fe—B magnetic product comprises forming the recycled Nd—Fe—B magnetic product having a composition substantially of W a R b A c with a concentration of the rare earth material R and a concentration of the elemental additive A that increases, on average, surrounding a primary Nd 2 Fe 14 B phase within the recycled Nd—Fe—B magnetic product, where W comprises Nd—Fe—B material from the waste magnetic assembly and indices a, b, and c comprise atomic percentages of the corresponding compositions or elements.

22. The method of claim 21 wherein forming the recycled Nd—Fe—B magnetic product comprises modifying an elemental concentration and an elemental composition of a grain boundary phase, on average, at a plurality of grain boundary regions that extend throughout the recycled Nd—Fe—B magnetic product by:

forming NdPrH 3 from H 2 processing gas and the rare earth material R; and

during sintering, transforming the NdPrH 3 to oxygen free NdPr.

23. The method of claim 1 , wherein:

sintering and magnetizing the homogenous powder to form the recycled Nd—Fe—B magnetic product comprises sintering and magnetizing the homogenous powder to form the recycled Nd—Fe—B magnetic product having a composition substantially of W a R b A c , where W comprises Nd—Fe—B material from the waste magnetic assembly;

indices a, b, and c comprise atomic percentages of the corresponding compositions or elements;

a(t) is the atomic percent of element t in the waste material W;

b(t) is the atomic percent of element t in the rare earth containing material R;

c(t) is the atomic percent of element t in the elemental additives A; and

a, b, c, a(t), b(t), and c(t) have values satisfying:

81 at. %≦a ≦99.9 at. %,

0.1 at. %≦b ≦1 at. %,

3 at. %−99.9 at. %*a(Co)≦c(Co)≦3 at. %−81 at. %*a(Co),

0.3 at. %−99.9 at. %*a(Cu)≦c(Cu)≦0.3 at. %−81 at. %*a(Cu),

77 at. %−99.9 at. %*(a(Fe)+a(Co))≦c(Fe)≦77 at. %−81 at. %*(a(Fe)+a(Co)),

a(Nd)+b(Nd)+a(Pr)+b(Pr)>0 at. %,

a(Nd)+b(Nd)+a(Pr)+b(Pr)+a(Dy)+b(Dy)+c(Dy)≦18 at. %,

a(Co)+b(Co)+c(Co)≦3 at. %,

a(Cu)+b(Cu)+c(Cu)≦0.3 at. %,

a(Fe)+b(Fe)+c(Fe)+a(Co)+b(Co)+c(Co)≦77 at. %, and

b(Nd)+b(Pr)+b(Dy)+c(Dy)≧0 at. %.

24. The method of claim 1 , wherein sintering and magnetizing the homogenous powder to form the recycled Nd—Fe—B magnetic product comprises sintering and magnetizing the homogenous powder to form the recycled Nd—Fe—B magnetic product having a composition substantially of W a R b A c , where W comprises Nd—Fe—B material from the waste magnetic assembly and indices a, b, and c comprise atomic percentages of the corresponding compositions or elements and the rare earth material R and the elemental additive A satisfy:

Nd[0.1−1 at. %*s(Nd), x],

Pr[0.1−1 at. %*s(Pr), y],

Dy[0.1−19 at. %*s(Dy), z],

Co[0 at. %, d],

Cu[0 at. %, e],

Fe[0 at. %, f],

wherein:

[m, n] means a range from a first value in a minimum interval m and a second value in a maximum interval n;

s(t) is the atomic percent of element t in starting composition;

x =18 at. %−[99, 99.9] at. % *(s(Nd)+s(Pr)+s(Dy));

y=18 at. %−[99, 99.9] at. % *(s(Nd)+s(Pr)+s(Dy));

z=18 at. %−[81, 99.9] at. %*(s(Nd)+s(Pr)+s(Dy));

d=3 at. %−[81, 99.9] at. %*s(Co);

e=0.3 at. %−[81, 99.9] at. %*s(Cu); and

f=77 at. %−[81, 99.9] at. %*(s(Fe)+s(Co)).

25. The method of claim 1 wherein demagnetizing the magnetic material from the waste magnet assembly by cyclic heating and cooling of the magnetic material comprises demagnetizing a waste magnet part, that comprises the magnetic material, from the waste magnet assembly to fragment the adhesives that bond the waste magnet part to a non-magnet part and to crack at least one coating layer selected from: an electrolytic black Epoxy, a Ni, a Ni—Cu, a Ni—Ni, a Ni—Cu—Ni, or a Zn coating layer of the waste magnet part.

26. The method of claim 25 wherein the cyclic heating and cooling comprises:

heating the magnetic material to a Curie temperature of the rare earth material R; and

cooling, after heating to the Curie temperature of the rare earth material R, the magnetic material at a rate of at least 100° C./sec.

27. The method of claim 1 , wherein sintering and magnetizing the homogenous powder to form the recycled Nd—Fe—B magnetic product that comprises 1.98 at. % oxygen or less comprises sintering and magnetizing the homogenous powder to form the recycled Nd—Fe—B magnetic product that comprises between 1.32 to 1.98 at. % oxygen.