In the world of magnetics, Alnico magnets stand out for their exceptional magnetic properties. They’re used in numerous industrial applications where reliability and strength are paramount.
The year 2005 marked a significant milestone in the evolution of these magnets, with the initiation of an ambitious R&D program aimed at enhancing the structural strength and energy grades of Cast Alnico 9. This initiative not only promised to revolutionize the capabilities of Alnico magnets, but also paved the way for innovations that would redefine their application across industries.
What are Alnico Magnets?
Alnico magnets – particularly Cast Alnico 9 – have long been the backbone of various technological and industrial developments.
Despite their widespread usage, these magnets faced inherent challenges, notably their susceptibility to cracking due to their columnar structures. This flaw was especially pronounced in Alnico 5-7 and Alnico 9 magnets, limiting their potential and application.
Breaking New Ground with R&D
Dedicated research and development efforts sought to address these limitations head-on. With meticulous research and experimentation, a superior grade of Cast Alnico 9 was developed.
This new formulation boasted improved physical strength, extended temperature and time stability, and the highest energy product and coercive force of any alnico material in the world, reaching [BHmax up to 11.5 MGOe]! Such advancements not only enhanced the durability of Cast Alnico magnets, but also expanded their utility in more demanding environments.
The Revolutionary “Bonded” Alnico Magnet
A significant innovation emerged with the introduction of Isotropic “Bonded” Alnico magnets. This novel approach involved blending Alnico powder with various binders, such as thermo-elastomeric (polyethylene, polyurethane), thermoplastic (nylon, PPS), or epoxy, and then pressing the mixture in a mold.
This process allowed for the creation of complex shapes like gear teeth with extremely tight dimensional tolerances, all without the need for secondary finishing. The benefits of insert molding further contributed to reducing overall system costs, making “Bonded” Alnico magnets a cost-effective and versatile option for a wide range of applications.
Manufacturing Cast Alnico Magnets
The manufacturing process of Cast Alnico magnets is a testament to precision engineering. From melting to casting, every step is meticulously managed to achieve the desired columnar or single crystal structure, with the magnetization direction carefully aligned parallel to the columnar grain axis.
This meticulous process ensures the optimized magnetic properties of Cast Alnico magnets, embodying the fusion of traditional craftsmanship and modern technological advancements.
Superior Performance in Applications
Cast Alnico magnets are renowned for their magnetic uniformity and temperature stability, offering excellent performance up to their maximum operating temperature.
Their resistance to chipping and ability to support complex magnetizing patterns make them ideal for a variety of applications, including magnetic suspension bearings for kWh meters, high-stability magnetic sensors, brushless DC motor magnets, and waveguide components, among others. The versatility and reliability of Alnico magnets underscore their critical role in advancing technological solutions across industries.
The strides made in the development of Cast Alnico magnets represent a remarkable achievement in the field of magnetics. The R&D program initiated in 2005 has not only overcome the traditional limitations of these magnets, but has also set new benchmarks for their energy product and coercive force. As we continue to explore the potential of Alnico magnets, their evolving applications promise to drive further innovation, ushering in a new era of technological advancements.
At BJA Magnetics, we remain committed to leading the charge in magnetic technology, empowering industries to achieve new heights of success. If you’re looking for the right Alnico magnet for your next application, contact BJA Magnetics today to get started!
