REE-Free Gap Magnets Materials for Sustainable Motor Applications As part of the IT-funded FutureMag project, MBN has developed an innovative class of rare-earth-free permanent magnets based on the (Fe,Co)₂(P,Si) magnetic alloy system. These “gap magnets” are engineered to bridge the performance and cost gap between ferrite magnets and rare-earth-based NdFeB magnets, offering sustainable magnet solutions without critical raw material dependencies. The REE-free magnetic powder is produced via MBN’s proprietary Mechanomade®, followed by controlled annealing to crystallize the ferromagnetic hexagonal phase. Post-processing optimization ensures particle size distribution and powder morphology suitable for powder metallurgy consolidation techniques and net-shape manufacturing. Consolidation into sintered permanent magnets is achieved through current-assisted hot pressing, Spark Plasma Sintering (SPS), or cold compaction with sintering, yielding near-net-shape magnetic components with retained crystallographic texture and optimized magnetic properties including coercivity, remanence, and energy product. (Fe,Co)₂(P,Si) permanent magnets target applications in compact electric motors, linear actuators, electromagnetic devices, and sensor systems, delivering significantly improved magnetic performance over ceramic ferrites at moderate production costs. Their rare-earth-free composition and powder metallurgy compatibility make them ideal for sustainable magnet manufacturing in e-mobility, electric vehicle traction motors, industrial automation, and renewable energy systems. COMPOSITION Fe – Co 13% – P 14% – Si 8% PROPERTIES Curie temperature 290 °C Anisotropy field 2 T Saturation magnetization 110 emu/g Materials for Sustainable Motor Applications
