Dresden 2026 – wissenschaftliches Programm

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MA: Fachverband Magnetismus

MA 52: Poster Magnetism III

MA 52.32: Poster

Donnerstag, 12. März 2026, 15:00–17:00, P4

Resource efficient recycling and additive manufacturing of Nd-Fe-B magnets — •Amrita Khan¹, Lukas Schäfer¹, Priyatosh Sahoo¹, Iliya Radulov², Mahmudul Hasan², Konstantin Skokov¹, Igor Lubomirsky³, and Oliver Gutfleisch¹ — ¹TU Darmstadt, Darmstadt, Germany — ²Fraunhofer IWKS, Hanau, Germany — ³Weizmann Institute of Science, Rehovot, Israel

Recycling Nd-Fe-B magnets is crucial for maintaining a sustainable supply of rare-earth elements for clean energy applications while significantly reducing the environmental impact and energy footprint. Additive manufacturing (AM) is a promising production route for functional magnetic materials, especially for achieving high geometric complexity, energy-efficient processing, and waste minimization. In this work, the PBF-LB/M process is used to directly produce permanent magnets, which are not yet optimized with regard to magnetic performance. The recycling of Nd-Fe-B scrap magnets and powder production is a critical step for successful processing via PBF-LB/M. In this study, different recycling processes are investigated: (i) hydrogen decrepitation, (ii) electrolytic decrepitation, and (iii) ultrasonic atomization, which are characterized regarding their particle size distribution, morphology, and flowability. The goal is to identify the influence of the powder properties on the PBF process and the resulting magnetic performance of additively manufactured magnets. This work was supported by the Volkswagen-Stiftung through the project MagCycleAM (9D878 Project No. 0071952-00).

Keywords: Permanent magnets; Recycling; Sustainable energy systems; E-mobility