An official website of the United States government
Bonded magnetic composites combine the cost-effectiveness, low density, and manufacturing flexibility of conventional polymer binders with the unique magnetic characteristics of magnetic powders/fillers to form multifunctional magneto polymeric composites that offer superior properties to conventional sintered magnets. In this study, a co-rotating twin screw extruder was used to fabricate 20 and 40 wt.% strontium ferrite/polyamide 4.6 bonded magnetic composites viable for fused filament fabrication 3D printing. The characterization conducted on the bonded magnetic composites was scanning electron microscopy, simultaneous differential thermogravimetry, and vibrating sample magnetometry. The microstructure of the bonded composite exhibited a uniform platelet morphology of the strontium ferrite magnetic particles. There was no observable depreciation in the melting transitions, which suggests a thermally resistant magnetic composite. An appreciable increment in % crystallinity of 13 and 20% for 20wt. % and 40wt. % strontium ferrites bonded magnets were observed. This is attributable to the heterogeneous nucleation phenomenon, where the metal powders act as nucleation sites for increased crystalline domains. The bonded composite exhibited significant magnetic anisotropy, with the remanence (Mr), which is the most important property for magnetic application significantly increasing to 49.8% along the easy direction in comparison to the hard axis. This suggests the viability of the fabricated bonded composites in viable in producing anisotropic bonded magnetic devices, which are considered to exhibit stronger magnetic properties.
more »
« less
This content will become publicly available on July 25, 2026
Review on mechanical, thermal, and magnetic performance of high-temperature thermoplastic bonded magnetic composites
Thermoplastic bonded magnetic composites combine the cost-effectiveness, low mass density, and manufacturing flexibility of conventional thermoplastics with the unique characteristics of magnetic powders/ fillers to form multifunctional magneto polymeric composites that offer superior properties to conventional materials. At elevated temperatures, the magnetic properties change significantly, and the polymer matrix no longer secures the magnetic particles and can rotate freely with respect to an externally applied magnetic field. This often happens at temperatures significantly below the melting point of the polymer. To extend the thermal window of bonded magnets beyond 175 ◦C (the typical temperature of rotors in motors and generators), poly- mers such as polyetheretherketone (PEEK), polyetherimide (PEI), or other high-temperature thermoplastics have been considered suitable binders for magnetic fillers. Another suggested approach is using a surface treatment to increase the adhesion between the polymer matrix and magnetic particles. In this review, the fabrication pro- cesses to make bonded magnets by injection molding and fused filament fabrication were discussed as well as their thermal, mechanical, and magnetic performance obtained via analytical and materials characterization methods. The magnetic properties of bonded permanent magnets manufactured via different techniques were discussed in terms of the most important single magnetic parameter known as “the maximum energy product- (BH)max, which can serve as a performance index for manufacturing bonded magnets. The energy product normalized on cost or mass density are used to provide insight on the performance of bonded magnets for ap- plications driven by cost or inertia. Finally, applications of high-performance thermoplastic-based magnetic composites that can be viable for stringent engineering devices such as sensors, actuators, motors, and generators were highlighted.
more »
« less
- Award ID(s):
- 2216440
- PAR ID:
- 10644317
- Editor(s):
- Zheng, Hao
- Publisher / Repository:
- www.elsevier.com/locate/jmmm
- Date Published:
- Journal Name:
- Journal of magnetism and magnetic materials
- Volume:
- 630
- ISSN:
- 1873-4766
- Page Range / eLocation ID:
- 173394
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
-
-
Polymer matrix composites have been used extensively in the aerospace and automotive industries. Nevertheless, the growing demand for composites raises concerns about the thermal stability, cost, and environmental impacts of synthetic fillers like graphene and carbon nanotubes. Hence, this study investigates the possibility of enhancing the thermomechanical properties of polymer composites through the incorporation of agricultural waste as fillers. Particles from walnut, coffee, and coconut shells were used as fillers to create particulate composites. Bio-based composites with 10 to 30 wt.% filler were created by sifting these particles into various mesh sizes and dispersing them in an epoxy matrix. In comparison to the pure polymer, DSC results indicated that the inclusion of 50 mesh 30 wt.% agricultural waste fillers increased the glass transition temperature by 8.5%, from 55.6 °C to 60.33 °C. Also, the TGA data showed improved thermal stability. Subsequently, the agricultural wastes were employed as reinforcement for laminated composites containing woven glass fiber with a 50% fiber volume fraction, eight plies, and varying particle filler weight percentages from 0% to 6% with respect to the laminated composite. The hybrid laminated composite demonstrated improved impact resistance of 142% in low-velocity impact testing. These results demonstrate that fillers made of agricultural wastes can enhance the thermomechanical properties of sustainable composites, creating new environmentally friendly prospects for the automotive and aerospace industries.more » « less
-
The major challenge to fabricate MXene/polymer composites are the processing conditions and poor control over the distribution of the MXene nanosheets within the polymer matrix. Traditional ways involve the direct mix of fillers and polymers to form a random homogeneous composite, which leads to inefficient use of fillers. To address these challenges, researchers have focused on the development of ordered MXene/polymer composite structures using various fabrication strategies. In this review, we summarize recent advances of structured MXene/polymer composites and their processing-structure-property relationships. Two main forms of MXene/polymer composites (films and foams) are separately discussed with a focus on the detailed fabrication means and corresponding structures. These architected composites complement those in which MXenes nanosheets are isotropically dispersed throughout, such as those formed by aqueous solution mixing approaches. This review culminates in a perspective on the future opportunities for architected MXene/polymer composites.more » « less
-
Stoebe, Thomas (Ed.)Rare-earth (RE) materials are currently used to fabricate permanent magnets through various additive manufacturing (AM) methods. Fused filament fabrication (FFF) is one of the most commonly used polymer-based AM methods and has recently been used to produce metal-matrix composites, known as “green parts,” using a metal powder-infused filament. The FFF method has gained much attention in various industries including the automotive, aerospace, and medical fields. Therefore, involving RE in the FFF process using magnetic powder-infused filaments promises to result in the fabrication of low-cost, efficient, and complex magnetic components based on application areas. This module introduces the FFF process and provides a case study for high school and technical college students to gain a fundamental understanding of how magnetic powders are infused and how parts are fabricated using this method.more » « less
-
We present a novel type of magnetorheological material that allows one to restructure the magnetic particles inside the finished composite, tuning in situ the viscoelasticity and magnetic response of the material in a wide range using temperature and an applied magnetic field. The polymer medium is an A-g-B bottlebrush graft copolymer with side chains of two types: polydimethylsiloxane and polystyrene. At room temperature, the brush-like architecture provides the tissue mimetic softness and strain stiffening of the elastomeric matrix, which is formed through the aggregation of polystyrene side chains into aggregates that play the role of physical cross-links. The aggregates partially dissociate and the matrix softens at elevated temperatures, allowing for the effective rearrangement of magnetic particles by applying a magnetic field in the desired direction. Magnetoactive thermoplastic elastomers (MATEs) based on A-g-B bottlebrush graft copolymers with different amounts of aggregating side chains filled with different amounts of carbonyl iron microparticles were prepared. The in situ restructuring of magnetic particles in MATEs was shown to significantly alter their viscoelasticity and magnetic response. In particular, the induced anisotropy led to an order-of-magnitude enhancement of the magnetorheological properties of the composites.more » « less
