A plethora of modern technologies rely on permanent magnets for their operation, including many related to the transition towards a sustainable future, such as wind turbines or electric vehicles. Despite the overwhelming superiority of magnets based on rare-earth elements in terms of the magnetic performance, the harmful environmental impact of the mining of these raw materials, their uneven distribution on Earth and various political conflicts among countries leave no option but seeking for rare-earth-free alternatives. The family of the hexagonal ferrites or hexaferrites, and in particular the barium and strontium M-type ferrites (BaFe₁₂O₁₉ and SrFe₁₂O₁₉), are strong candidates for a partial rare-earth magnets substitution, and they are indeed successfully implemented in multiple applications. The manufacturing of hexaferrites into dense pieces (i.e. magnets) meeting the requirements of the specific application (e.g. magnetic and mechanical properties, shape) is not always straightforward, which has in many cases hampered the actual substitution at the industrial level. Here, past and on-going research on hexaferrites sintering is reviewed with a historical perspective, focusing on the challenges encountered and the solutions explored, and correlating the sintering approaches with the magnetic performance of the resulting ceramic magnet.

In this review article, we focus on the relationship between permanent magnets and the electric motor, as this relationship has not been covered in a review paper before. With the increasing focus on battery research, other parts of the electric system have been neglected. To make electrification a smooth transition, as has been promised by governing bodies, we need to understand and improve the electric motor and its main component, the magnet. Today’s review papers cover only the engineering perspective of the electric motor or the material-science perspective of the magnetic material, but not both together, which is a crucial part of understanding the needs of electric-motor design and the possibilities that a magnet can give them. We review the road that leads to today’s state-of-the-art in electric motors and magnet design and give possible future roads to tackle the obstacles ahead and reach the goals of a fully electric transportation system. With new technologies now available, like additive manufacturing and artificial intelligence, electric motor designers have not yet exploited the possibilities the new freedom of design brings. New out-of-the-box designs will have to emerge to realize the full potential of the new technology. We also focus on the rare-earth crisis and how future price fluctuations can be avoided. Recycling plays a huge role in this, and developing a self-sustained circular economy will be critical, but the road to it is still very steep, as ongoing projects show.

Development of refractory metals for application as plasma-facing armour material remains among priorities of fusion research programmes in Europe, China and Japan. Improving the resistance to high temperature recrystallization, enhancing material strength to sustain thermal fatigue cracking and tolerance to neutron irradiation are the key indicators used for the down selection of materials and manufacturing processes to be applied to deliver engineering materials. In this work we investigate the effect of neutron irradiation on mechanical properties and microstructure of several tungsten grades recently developed. Neutron irradiation campaign is arranged for screening purposes and therefore is limited to the fluence relevant for the ITER plasma facing components. At the same time, the neutron exposure covers a large span of irradiation temperatures from 600 up to 1000 °C. Four different grades are included in the study, namely: fine-grain tungsten strengthened by W-carbide (W–4wt.% W₂C), fine-grain tungsten strengthened by Zr carbides (W–0.5% ZrC), W alloyed with 10 at.% chromium and 0.5 at.% yttrium (W–10Cr–0.5Y) and technologically pure W plate manufactured according to the ITER specification by Plansee (Austria). The strengthening by W₂C and ZrC particles leads to an enhanced strength, moreover, the W–0.5ZrC material exhibits reduced DBTT (compared to ITER specification grade) and is available in the form of thick plate (i.e. high up-scaling potential). The W–10Cr–0.5Y grade is included as the material offering the self-passivation protection against the high temperature oxidation.

In the last few years, significant effort has again been devoted to ferrite-based permanent magnet research due to the so-called rare-earth crisis. In particular, a quest to enhance ferrites maximum energy product, BH _max, is underway. Here, the influence of composition and sintering conditions on the microstructure and consequently magnetic properties of strontium ferrite-based hybrid composites was investigated. The powder mixtures consisted of hydrothermally synthesised Sr-ferrite with hexagonally shaped platelets with a diameter of 1 μm and thickness up to 90 nm, and a soft magnetic phase in various ratios. Powders were sintered using a spark plasma sintering furnace. The crystal structure, composition and microstructure of the starting powders and hybrid magnets were examined. Their magnetic properties were evaluated by vibrating sample magnetometer, permeameter and by single-point-detection measurements.

Composites of magnetically hard and soft phases are present in multiple and diverse applications, ranging from bulk permanent magnets in motors and generators to state-of-the-art recording media devices. The nature of the magnetic coupling between the hard and soft phases is of great technological relevance, as the macroscopic properties of the functional composite material ultimately depend on the atomic-scale interactions between phases. In this work, the hard/soft bilayer system SrFe ₁₂ O ₁₉ /Co has been studied based on photoemission electron microscopy combined with x-ray absorption and magnetic circular dichroism. Our experiments show that the magnetization of the hard magnetic oxide has a direction perpendicular to the layer plane, whereas the magnetization of the soft metallic overlayer remains in-plane. As a consequence, the magnetic domain patterns observed for the hard and soft phases are very different and completely uncorrelated to one another, indicating that no soft spins align with the hard phase by pure magnetodipolar arguments. The results are understood as the consequence of an absence of exchange-coupling between phases, in a scenario in which the shape anisotropy of the soft layer overcomes the Zeeman energy of the perpendicular magnetic field generated by the hard ferrite. Micromagnetic simulations of our system predict that low degrees of exchange-coupling effectively prevent substantial softening of the composite and lead to the alignment of soft and hard magnetic moments. A strategy thus emerges for the development of future hard-soft magnets, based on minimizing the degree of exchange-coupling while avoiding complete uncoupling.