Sm₂TM₁₇ sintered magnets (TM = Co, Fe, Cu, Zr) are utilised in high-temperature rotor applications due to their stable magnetic properties at elevated temperatures of 200–350 °C. However, Sm and Co are critical elements, and the reliance on virgin material supply chains must be reduced. Hydrogen decrepitation (HD) could facilitate magnet-to-magnet recycling of scrap material, but the milling characteristics of the powders generated by HD requires investigation. Sm₂TM₁₇ sintered magnets were exposed to 18 bar and 2 bar hydrogen pressure at 100 °C for 72 h and then knife-milled, roller ball-milled, and planetary ball-milled for varying milling times utilising a variety of surfactants. The particle size and morphology of the powders were investigated, and sintered magnets manufactured from chosen powders were characterised in terms of composition, density, microstructure, and magnetic properties. Knife milling for two minutes showed major particle size reductions of 70 and 82% in D50 for 18 bar and 2 bar samples respectively. Roller ball milling trials showed that a cyclohexane and oleic acid mixture was the most effective at reducing particle size, reducing D10, 50, and 90 by 92, 91, and 80% respectively. Knife milling HD powder for two minutes and then planetary ball milling this powder in a cyclohexane and 1 wt.% oleic acid mixture generated a particle size distribution of 1.3–6.8 µm. This powder formed a sintered compact with a density 0.08 g/cm³ lower than the as-received material. Sm losses due to oxidation and sublimation in addition to carbon impurities from surfactant usage caused the precipitation of an α-Fe/Co phase and formed ZrC phases respectively. Sm-hydride additions of 2–3 wt.% mitigated the formation of the α-Fe/Co phase, but ZrC phases remained and likely prevented cell structure formation and inhibited domain wall pinning in recycled magnets.

Within aerospace and automotive manufacturing, the majority of quality assurance is through inspection or tests at various steps during manufacturing and assembly. Such tests do not tend to capture or make use of process data for in-process inspection and certification at the point of manufacture. Inspection of the product during manufacturing can potentially detect defects, thus allowing consistent product quality and reducing scrappage. However, a review of the literature has revealed a lack of any significant research in the area of inspection during the manufacturing of terminations. This work utilises infrared thermal imaging and machine learning techniques for inspection of the enamel removal process on Litz wire, typically used for aerospace and automotive applications. Infrared thermal imaging was utilised to inspect bundles of Litz wire containing those with and without enamel. The temperature profiles of the wires with or without enamel were recorded and then machine learning techniques were utilised for automated inspection of enamel removal. The feasibility of various classifier models for identifying the remaining enamel on a set of enamelled copper wires was evaluated. A comparison of the performance of classifier models in terms of classification accuracy is presented. The best model for enamel classification accuracy was the Gaussian Mixture Model with expectation maximisation; it achieved a training accuracy of 85% and enamel classification accuracy of 100% with the fastest evaluation time of 1.05 s. The support vector classification model achieved both the training and enamel classification accuracy of more than 82%; however, it suffered the drawback of a higher evaluation time of 134 s.

Sm₂TM₁₇ sintered magnets, (where TM = Co, Fe, Cu, Zr), are typically utilised in high temperature magnetic applications due to their magnetic properties being very stable at 200–350 °C. Sm and Co are critical materials and need to be recycled to reduce reliance on virgin material supply chains. This work explored HD processing of Sm₂TM₁₇ sintered magnet production scrap as a potential recycling technique. Sintered magnet scrap was initially analysed compositionally, microstructurally and magnetically to determine issues with magnet quality. Scrap material was then HD processed at 18 bar and 2 bar at temperatures between 25–300 °C. The resultant material was characterised in terms of hydrogen content, particle size, degassing behaviour and unit cell expansion. Production scrap magnets exhibited irregular demagnetisation traces with poor domain wall pinning behaviour. Non-magnetic ZrC inclusions likely prevented cell structure formation locally and hence were poor domain wall pinning sites. Scrap material processed at 18 bar and 2 bar required temperatures of 100 °C to allow for the greatest extent of HD reaction, reaching 0.299 Wt.% and 0.323 Wt.% hydrogen respectively. The HD behaviour of production scrap material was comparable to commercial grade magnets. Therefore, HD is a potentially viable technique for recycling Sm₂TM₁₇ sintered magnet production scrap.

Obscure they may be, but the chapter titles of this book hide some well-researched, thought-provoking essays on aspects of science where we have not, and may never, reach a definitive answer.