Sintered rare-earth permanent magnets (REPMs), more specifically Neodymium-Iron-Boron (NdFeB) and Samarium-Cobalt (SmCo) varieties, are foundational to numerous modern technologies due to their unmatched magnetic strength. Their applications are widespread, from consumer electronics and medical devices like MRI machines to critical green technologies such as high efficiency motors in electric vehicles and generators in wind turbines. However, the extraordinary performance of these magnets is not simply a result of their chemical composition. It is critically dependent on achieving a precise and optimized microstructure, which is primarily developed through a powder metallurgy process.

Figure 1: REPMs can be found in a variety of consumer products, high-tech devices and critical green technologies

This manufacturing route involves several high temperature stages, most notably sintering and multi-stage heat treatments. Within this process, vacuum furnaces are a pivotal technology. They provide the stringently controlled atmospheric conditions essential for densification and for developing the specific microstructural features that give these advanced materials their exceptional magnetic properties. In this article, we will explore the critical functions of vacuum furnaces in the sintering and heat treatment of high performance NdFeB and SmCo magnets.

Powder metallurgy route for REPMs

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The TAV Performance LAB is a key strategic resource within the Research and Development (R&D) department of TAV VACUUM FURNACES, a centre of excellence where technology and innovation come together to create cutting-edge vacuum furnaces solutions.

Our laboratory houses a variety of highly specialised furnaces designed to support research and development activities aimed at perfecting heat treatment processes. Thanks to the wide range of technical features, numerous fundamental tests can be performed on metallic and ceramic materials, ranging from the most common heat treatment applications to advanced processes such as sintering, brazing and thermochemical treatments.

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Minting is a perfect example of where art meets science and technical expertise.

Masterfully designed coin artworks, created by skilled artists, are engraved into steel using a computer-controlled engraving machine to produce a reduction die.

The reduction die is then placed in a hydraulic press, where through high pressure, ranging from 100 to 400 tons, the design is transferred onto a softened steel block. This process results in a master die that contains a negative impression of the coin’s design.

The master die is then subjected to a hardening treatment and subsequently used to produce several negative dies, or working dies, intended for the actual coining process.

Once pressed, the minting dies are shaped, hardened, and sometimes plated to enhance durability. Depending on the type of coin being produced, a single set of minting dies can be used to strike millions of coins.

The minting industry relies on the precision and longevity of its tools and dies to sustain high production volumes. During the coining process, the workpiece is subjected to intense pressure, inducing plastic deformation on its surface to imprint the negative image onto the coin. Typically, two metallic dies strike the coin simultaneously, one for each side of the workpiece, ensuring sharp, detailed impressions with every strike.

Figure 1: A tool steel coining die (courtesy of Staatliche Münzen Baden-Württemberg)

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In 2024 we celebrated an important milestone: 40 years of activity!

Since 1984, we have been committed to providing solutions for vacuum heat treatments, responding to the most different needs with cutting-edge technology, uncompromising quality and Italian craftsmanship. To celebrate this special anniversary, we have made our new corporate video.

 The video, set in the TAV VACUUM FURNACES headquarters, is characterized by dynamic and engaging images that show the entire production process and underline the synergy between technology, innovation and human expertise. Guided by an operator, we witness fast and fluid scenes alternating between moments of design on paper, 3D models and computer renderings, up to the complete construction of the furnace. The visual narrative highlights both the customization of TAV VACUUM FURNACES products and the human side, with slower shots that break the rhythm to emphasize the attention to detail and precision of the work done.

This video is not a retrospective of the past, it is above all a look into the future. It shows the passion and dedication we put into every project, the attention to detail that distinguishes us and the continuous search for innovation that pushes us to overcome limits.

What you will find in the video:

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“Bright annealing” is a general term referring to several heat treatment processes performed on metal alloys to remove residual stresses, modify their microstructure and, generally speaking, improve their mechanical properties. Regardless of the specific material and heat treatment recipe applied, the aim of bright annealing is always to obtain surfaces that are shiny, reflective, and oxide-free, in one word: bright.

For that reason, bright annealing needs to be performed in a controlled environment, such as a vacuum, inert gas or a reducing atmosphere, to prevent oxidation and contamination, ensuring the metal retains its original luster.

Vacuum furnaces are of course the perfect machines to perform bright annealing treatments: by effectively eliminating air and other gases that could cause oxidation or contamination of the metal surface, we can always be sure to get our heat-treated parts as bright as possible, right?

Well, yes and no. In reality, several factors are influencing the surface appearance of metal parts after the heat treatment; only a careful optimization of the process parameters in relation to the material can ensure its success.

Let’s have a look more in detail at what are the key factors in that respect and how they will influence the outcome of our bright annealing treatment!

Principles of Bright Annealing

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