Designing with Dysprosium Free Permanent Magnets www.mqitechnology.com

1. Sintered Neo Replacement:
Dysprosium-free Rare Earth Permanent Magnet
Motors

2. Sintered Neo Replacement
• Fundamentals in dysprosium (Dy) market will result in
significantly higher prices
– Increasing demand due to growth in sintered Nd
market
– Insufficient supply
• When possible, magnet users should design applications
with magnets without Dy
– Magnets using MQPTM grades do not rely on Dy
• Application performance is comparable and can be
optimized if MQPTM is “designed in”

3. Rising prices of rare earth metals:
Soaring prices of Dy

4. Escalating Price of Dy:
Fundamental supply-demand imbalance
High demand Low output
in Dy rich sintered neo applications
Estimated Production in 2010*
Yttrium
Dysprosium Erbium
11.7%
2.4% 1.1%
Lanthanum
Terbium 24.6%
Gadolinium 0.6%
1.6%
Europium
1.0%
Samarium
2.0%
Neodymium
20.7%
Cerium
Praseodymium 29.0%
5.4%
*Source:National Development and Reform Commission (NDRC) Report April 2011

5. Dy Rich Sintered Applications
Technology Assumption Low Penetration High Penetration
Wind Onshore Wind Turbine Additional Capacity (GW) 23.6 48.6
Wind Offshore Wind Turbines Additional Capacity (GW) 4.9 17
Deployment in
Vehicles Sales of Hybrid Electric Vehicles (HEVs) (millions) 4.2 19.1
2025
Vehicles Sales of Plug-in Hybrid Electric Vehicles (PHEVs) (millions) 0.002 13.2
Vehicles Sales of All Electric Vehicles (AEVs) (millions) 0.001 4.6
Wind Onshore Wind Turbines using RE Magnets 10% 25%
Market Share Wind Offshore Wind Turbines using RE Magnets 10% 75%
Vehicles HEVs, PHEVs, and AEVs using RE Magnet Motors 100% 100%
Technology Assumption Low Intensity High Intensity
Wind Average Weight of Magnets per MW (kgs) 400 600
Vehicles Average Weight of Magnets per vehicle (kgs) 1 2
Materials Wind and
% Weight of Magnets that is Neodymium 31% 31%
Intensity Vehicles
Wind and
% Weight of Magnets that is Dysprosium 5.50% 5.50%
Vehicles
Source: Critical Materials Strategy by U.S Department of Energy (Dec 2010)
http://www.energy.psu.edu/oeo/ree/reports/criticalmaterialsstrategy121710.pdf

6. Current Rare Earth Types and Content
Source: Critical Materials Strategy by U.S Department of Energy (Dec 2010)
http://www.energy.psu.edu/oeo/ree/reports/criticalmaterialsstrategy121710.pdf

7. Low levels of Dy occurrence
Low levels of Dy present
Yttrium
Dysprosium Erbium
11.7%
2.4% 1.1%
Lanthanum
Terbium 24.6%
Gadolinium 0.6%
1.6%
Europium
1.0%
Samarium
2.0%
Neodymium
20.7%
Cerium
Praseodymium 29.0%
5.4%
Estimated Production in 2010*
*Source:National Development and Reform Commission (NDRC) Report April 2011

8. Possible new sources of Rare Earths:
Dy contents are low
Assumed Additional Production by 2015 Total
Additional
Mountain Pass Mt. Weld Nolans Bore Nechalaco Dong Pao Hoidas Lake Dubbo Zirconia Production by
(USA) (Australia) (Australia) (Canada) (Vietnam) (Canada) (Australia) 2015
Lanthanum 6,640 3,840 2,000 845 1,620 594 585 16,124
Cerium 9,820 6,855 4,820 2,070 2,520 1,368 1,101 28,554
Praseodymium 860 810 590 240 200 174 120 2,994
Neodymium 2,400 2,790 2,150 935 535 657 423 9,890
Samarium 160 360 240 175 45 87 75 1,142
Europium 20 90 40 20 - 18 3 191
Gadolinium 40 150 100 145 - 39 63 537
Terbium - 15 10 90 - 3 9 127
Dysprosium - 30 30 35 - 12 60 167
Yttrium 20 60 - 370 35 39 474 998
TOTAL 19,960 15,000 9,980 4,925 4,955 2,991 2,913 60,724
Source: Critical Materials Strategy by U.S Department of Energy (Dec 2010)
http://www.energy.psu.edu/oeo/ree/reports/criticalmaterialsstrategy121710.pdf

9. Why does Sintered Neo need Dy?
• Sintered neo is much more
inclined to have a knee in the
second quadrant engineering
curve at elevated temperature
– Due to high remanence
values of sintered neo
– Results in irreversible losses
in motor
• Compensation for this knee,
motor companies could
– Increase the magnet length
– Adding Dy to enhance
coercivity

10. Typical Sintered Neo Alloy composition
Type T.R.E NdPr Dy Gd Tb Fe Co B Al
N35H 32.4 27.23 3.3 1.9 0 64.4 1 1 1
N35SH 33 29.64 3.4 0 0 64.8 0 1.1 1
N35UH 32.1 26.92 5 0.2 0 65 1 1 1
N38H 32.2 29.04 3.2 0 0 65.1 1 1 0
N38SH 31.9 28.29 3.6 0 0 65.4 1 1 1
N38UH 31.7 25.62 6.1 0 0 65.8 0.9 1 0
N42H 31 29.3 1.8 0 0 66.5 0.7 1 0
N42SH 30.4 26.66 3.3 0 0.4 66.9 1 1 0
N42UH 31.7 27.24 3.8 0 0.7 65.8 0.9 1 0
N45H 31.4 29.45 2 0 0 66.1 0.9 1 0
N45SH 30 27.06 0.8 0 2.1 67.4 0.9 1 0
N45UH 30.1 26.61 0.8 0 2.7 67.3 0.9 1 0
MQP-B 25.4 25.41 0 - - 73.4 - 1 -
Typical sintered Nd grades contain up to 6% of Dy

11. Advantages of Bonded Neo
• MQPTM has very good
linearity in the second 25C-MQP-B+-20056 125C-MQP-B+-20056 25C-MQP-14-12 125C-MQP-14-12
quadrant engineering curve 8
up to temperatures as high as Load line at stall Load line at no-load
7
150-180oC 6
• Able to achieve equivalent 5
B (kG)
performance 4
3
• No significant increase in
2
motor size
1
• All MQPTM grades are Dy 0
free! -7 -6 -5 -4 -3 -2 -1 0
H (kOe)

12. CASE STUDY www.mqitechnology.com
Copyright © 2011 Magnequench Neo Powders Pte Ltd

13. Case Study 1:
Comparison of the Sintered Neo and
Bonded Neo based Motors
4-Pole PMDC Motor with 4-Pole PMDC motor with
Parameter
Sintered Neo Magnets Bonded Neo Magnets
4-Arc Sintered neo Isotropic Bonded Neo
Type of Magnet
(N35SH) (MQP-14-12)
Total motor weight (gm) 107.80 143.34
Length of the motor (mm) 10.00 12.00
Overall diameter (mm) 42.00 46.75
Total copper weight (gm) 12.70 23.80
Total magnet weight (gm) 14.20 24.94
Length of Air gap (mm) 0.80 0.80
Current at 80 mN-m (A) 11.06 10.20
Efficiency at 80 mN-m (%) 73.13 75.27

14. Case Study 1:
Chemical Composition and Magnet
Characteristics for Sintered Neo Magnet
ICP Test Result
Element Nd Tb La Ce Pr Sm Dy Gd T.R.E
% 18.731 0.151 0 0.031 5.862 0.026 2.491 1.680 28.972

15. Case Study 1:
Comparison of Key Physical Dimensions for the
Sintered Neo and Bonded Neo based Motors
Sintered Neo Motor Bonded Neo Motor

16. Case Study 1:
Comparison of Motor Characteristics for the Sintered Neo
and Bonded Neo based Motors
Torque-efficiency and Torque-output power
characteristics
Torque-speed and Torque-current
characteristics

17. Case Study 1:
Comparison of Key Physical Parameters and Cost
for the Sintered Neo and Bonded Neo based Motors

18. Case Study 2:
Comparison of the Sintered Neo and
Bonded Neo based Motors
4-Pole PMDC Motor 4-Pole PMDC Motor 4-Pole PMDC motor
Parameter with Sintered Neo with Sintered Neo with Bonded Neo
Magnets Magnets Magnets
4-Arc Sintered neo 4-Arc Sintered neo Isotropic Bonded Neo
Type of Magnet
(N35SH) (N35) (MQP-B+-20056)
Dy content ~3% 0-0.5% 0%
Total motor weight (gm) 314.90 451.4 412.50
Length of the motor (mm) 18.00 23.00 20.00
Overall diameter (mm) 57.50 60.72 63.90
Total copper weight (gm) 29.80 21.3 57.10
Total magnet weight (gm) 29.10 56.5 37.30
Length of Air gap (mm) 0.55 0.55 0.55
Current at 220 mN-m (A) 11.08 10.55 11.21
Efficiency at 220 mN-m (%) 73.76 74.59 74.09

19. Case Study 2:
Comparison of Key Physical Dimensions for the Sintered Neo
and Bonded Neo based Motors
Sintered Neo (35SH) Sintered Neo (N35) Bonded Neo Motor

20. Case Study 2:
Comparison of Motor Characteristics for the
Sintered Neo and Bonded Neo based Motors
Torque-efficiency and Torque-output power
characteristics
Torque-speed and Torque-current
characteristics

21. Case Study 2:
Comparison of Key Physical Parameters and Cost for
the Sintered Neo and Bonded Neo based Motors

22. Case Study-3 – Comparison of the Sintered
Neo and Bonded Neo based Motors
4-Pole PMDC Motor 4-Pole PMDC motor
Parameter with Sintered Neo with Bonded Neo
Magnets Magnets
4-Arc Sintered neo Isotropic Bonded Neo
Type of Magnet
(N27SH or N30SH) (MQP-14-12)
Total motor weight (gm) 204.35 237.00
Length of the motor (mm) 15.50 19.25
Overall diameter (mm) 44.10 49.79
Total copper weight (gm) 28.09 18.60
Total magnet weight (gm) 18.47 39.80
Length of Air gap (mm) 0.57 0.57
Current at 190 mN-m (A) 27.08 26.99
Efficiency at 190 mN-m (%) 74.30 73.04

23. Case Study 3:
Chemical Composition and Magnet
Characteristics for Sintered Neo Magnet
ICP Test Result
Element Nd La Ce Pr Sm Dy Tb Gd T.R.E
% 21.204 0.004 0.028 6.047 0.000 4.087 0.034 0.109 31.479

24. Case Study 3:
Comparison of Key Physical Dimensions for the Sintered Neo
and Bonded Neo based Motors
Sintered Neo Motor Bonded Neo Motor

25. Case Study 3:
Comparison of Motor Characteristics for the
Sintered Neo and Bonded Neo based Motors
Torque-efficiency and Torque-
output power characteristics
Torque-speed and Torque-
current characteristics

26. Case Study 3:
Comparison of Key Physical Parameters and Cost for
the Sintered Neo and Bonded Neo based Motors