Magnetics 2012

Last week Moyer of MagnaTech P/M Labs attended a two day conference to obtain an update on activity in the magnetic field. The conference was oriented toward new materials, processes, and applications that will require magnetic assemblies. Of these, perhaps offshore windmills, requiring larger motors with minimum maintenance are perhaps the newest
as a challenge for today's applications. There was great concern about the availability and the cost of iron-neodymium-boron magnets. In 1990 General Motors sold their technology to the Chinese. I am told that all iron-neodymium-boron magnets are now manufactured in China. These kinds of magnets have the highest energy product and are therefore a requirement for the introduction of the electric car to the market, as well as new windmill drive requirements. In addition to the Chinese monopoly of the market, little research has been conducted in the United States to innovate new higher energy product alloys or improve additional alloys such as ferrites and Alnicos to satisfy some of the requirements of the developing market. Recently the Air Force has submitted a BAA and the Department of Energy is about to request Phase I SBIRs designed to satisfy these emerging markets. MagnaTech will be submitting a white paper to adress the requirements required of the Air Force BAA, and expects to write a proposal requesting a Phase I award for an idea of an alloy that we believe has potential for higher energy product material. If you are interested in new magnetic materials and their design, contact MagnaTech to explore technology, which they have patented, that could satisfy some of the advanced material requirements.MagnaTech has test equipment to support materials research and also provides a short course to those wishing to come up to speed in this newly developing industry.

New Patent

MagnaTech has been informed that they have been awarded a patent that uses gaseous nitrogen in a nano state to alloy nitrogen with high strength powders. When consolidated using HIP technology, the powders become dense and exhibit excellent wear resistance, corrosion resistance, and toughness. MagnaTech now owns two patents, and has three additional patents pending.
In addition, MagnaTech was issued a purchase order yesterday to begin a study of P/M magnetic alloys to be tested for electromagnetic shielding. MagnaTech is doing more and more outside service testing for customers that need to know the properties of these special purpose nickel iron alloys. The equipment required to test these materials is expensive, and is concentrated primarily with the material manufacturers. Therefore, when a parts producer requires outside verification of properties supplied by the material producers, they look to MagnaTech to substantiate the documented properties. The materials are used for DC or pulsed DC applications, and require high magnetic permeability and low coercive field. These properties are difficult to achieve, and are important to the end user. If you have a need for these services, MagnaTech may have your solution. In addition, Moyer of MagnaTech offers one or two day short courses, including magnetic theory, magnetic materials and test methods. Call or email us if you have need of these services.

MagnaTech Gains New Customer

This was a great week for MagnaTech. Not only did we receive a Phase II Department of Defense contract but we were notified that we have been selected to do magnetic measurements for a defense contractor who makes gyroscopes for missiles. MagnaTech has equipment to make direct current measurements of magnetic induction, residual magnetism, relative maximum permeability and coercive field according to ASTM Test Method A596, Standard Test Method for Direct-Current Magnetic Properties of Materials Using the Ballistic Method and Ring Specimens. This and ASTM Specification A773 are the preferred specifications for the measurement of the direct-current magnetic properties of Nickel-Iron soft magnetic alloys.
MagnaTech this week has also submitted a white paper for a BAA proposal to develop a system of ternary alloys containing iron,aluminum and phosphorus.MagnaTech expects delivery of 440C stainless steel and AISI 9310 steel this week to begin expansion of the program to investigate high temperature carburizing of Pyrowear 675 and
AISI 4330 V already in inventory, as well as the two steels expected this week.

MagnaTech Is Awarded Phase II Contract

MagnaTech has just signed a two year contract to continue work on carburization and nitriding processes that are awaiting patent approval. The first year of the new contract adds low alloy steels to the alloys studied in addition to the martensitic stainless steels that have been successfully carburized and nitrided.In addition, the process will be scaled up in the first year to simulate production loads of hook points. The second year of the contract will translate the process over to the direct production of prototype hook points and development of a machine to test the wear, corrosion and fatigue resistance of the hook points under simulated conditions prior to actual performance.If the work is successfully completed, MagnaTech will prepare to commercialize the technology.
In addition to the above new contract, MagnaTech is currently considering revision of work for which they contracted with the Department of Energy. That study involved the development of iron aluminum alloys for magnetic applications. At that point, the new alloys satisfied all required properties for emerging more efficient electric motors. One hurdle remained, and that was that the automotive industry wanted a magnetization of 15,000 gauss (1.5 teslas) at an applied field of 100 oersteds (7960 A/m). Owing to the well known thermite reaction, it was not possible to achieve this goal because of the expansion that occurred during the alloying stage of processing. MagnaTech believes that they have a modification of their original concept that will permit this obstacle to be overcome, as well as improve the original magnetic properties of the alloys. MagnaTech would be interested in discussions on the technology they have developed or are currently in the process of developing.

MagnaTech Submits Proposal to NSF

MagnaTech has a new idea for recovering phosphorus from waste material and making it a useful product. MagnaTech intends to accomplish this by using a recently developed toroidal phase separator to react the phosphorus in the waste product and ultimately produce an alloy that can be used for magnetic and strength applications in motors, and transmissions in automobiles. Phosphorus is presently a contaminant in waste water that must be removed to make our fresh water supply useable. Currently there are processes to accomplish this. However, the phosphorus is eventually returned to the ground as fertilizer and must be removed again. One sewerage plant has told us that removal of the sludge to landfill costs $900,000 per year. In addition, current ores to produce phosphorus and its compounds are reported to be depleted by 2050. To make matters worse, EPA is currently suing ongoing operators of the mines for contamination of waters in the region.
MagnaTech believes that they can develop a process whereby the phosphorus in waste product can be recovered without a threat to the environment, and convert the phosphorus recovered to useful product. Several interested parties are considering support of the new technology.
MagnaTech has also completed all financial adaptations to change their accounting system to comply with cost plus fixed fee projects awarded through government contract. MagnaTech currently awaits approval to resume scale-up of a carburizing or nitriding process developed that is in the process of being patented for protection of hook points from wear and corrosion.
MagnaTech specializes in custom research in materials and materials processing. As such, MagnaTech is interested in discussions on how we can help you resolve your problems in a world that examines bottom line economics and not customer control of value added to produce more desirable products.

MagnaTech Approved to Receive Government Contracts

MagnaTech has just received the good news that their audit has been completed successfully. MagnaTech is now awaiting issuance of a Phase II SBIR contract from the Navy to continue development of their patent pending process for carburizing or nitriding of martensitic stainless steel surfaces to improve protection of hook points from abrasion, while maintaining toughness and excellent corrosion resistance in sea water. When issued, the contract will be for a two-year program to scale up the present processes to produce furnace loads of carburized or nitrided hook points. In addition to the martensitic stainless steels, MagnaTech will also explore extending the present processes to include the carburizing or nitriding of low alloy steels currently designed for this purpose. Within the second year of the contract, MagnaTech will transfer the optimum conditions to surface harden actual hook points. MagnaTech will also, with the assistance of Bud Labs, Rochester, New York, construct a test rig to test the carburized or nitrided surfaces under simulated test conditions.
In addition to the major project about to be initiated, MagnaTech continues to grow a market for the magnetic testing of materials that are being designed by other companies to improve the magnetic performance of materials slated for new designs, in particular small fractional motors and fast nickel irons for applications such as solenoids.

Magnatech Completes Federal Preaudit

MagnaTech believes that it is now qualified to receive government research projects. This statement results from an extensive adjustment of MagnaTech financial practices to conform with government requirements for cost plus fixed fee contracts. MagnaTech is currently awaiting a Phase II SBIR contract to continue work pertaining to carburization and nitriding processes, which are currently being reviewed for patent award. The Phase II contract, when offered,would concentrate a two year effort to research the possibility of including the technology to carburize or nitride less costly alloy steels to provide improved wear and corrosion resistance. In addition, the process will be scaled up to produce pilot loads of simulated parts for preparation for production. MagnaTech is interested in talking with interested parties regarding this new technology designed to reduce production time, produce cleaner parts and to improve the environment.