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How are magnets made?

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There are several processes for making magnets, but the most common method is called Powder Metallurgy. In this process, a suitable composition is pulverized into fine powder, compacted and heated to cause densification via “liquid phase sintering”. Therefore, these magnets are most often called sintered magnets. Ferrite, Samarium Cobalt (SmCo) and neodymium-iron-boron (neo) magnets are all made by this method. Unlike ferrite, which is a ceramic material, all of the rare earth magnets are metal alloys.

HOW SMCO AND NEO MAGNETS ARE MADE

Suitable raw materials are melted under vacuum or inert gas in an induction melting furnace. The molten alloy is either poured into a mold, onto a chill plate, or processed in a strip caster – a device that forms a thin, continuous metal strip. These cured metal “chunks” are crushed and pulverized to form a fine powder ranging from 3 to 7 microns in diameter. This very fine powder is chemically reactive, capably of igniting spontaneously in air and therefore must be protected from exposure to oxygen.

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