Research Trands on Rare Earth and Critical Elements in JapanJ p

K. Hono

N ti l I tit t f M t i l S i (NIMS)National Institute for Materials Science (NIMS)Tsukuba, 305-0047, Japan

Energy Energy use cleaning

Critical Elements for Energy and EnvironmentCritical Elements for Energy and Environmentgy

Generation, conversion, storagegy

Heat, actuation, illumination, informationg

Fuel CellSolar Cell Battery Thermo-El t i

Motor LEDElectronics

CatalystElectric

Motor LED Catalyst

GaAs

PtRh

LiCo Bi Dy Ga

In

AgAuPd

PtAsInCdRu

RhLaCeGd

CoNiR.E.

TeCoSb

NdSmCoB

InLaEuY

PdRhInW

PdRhR.E.

Ru B Y W

Research Institutes and Funding System in Japan

METIMEXT

Ministry of Education, Culture, Sports, and Science and Technology (MEXT)

Ministry of Economy, Trade and Industry (METI)

JST JSPS NEDO

funding agencies funding agency

UniversitiesNIMS AIST

Strategic Research Applied Research

RIKEN

Basic ResearchIndustry

Elements Science and Technology Elements Science and Technology ProjectProject- Designing Material Functions through Fundamental Research on Elements’ Roles -

BackgroundRare earths and other rare metals utilized for electronics automotives

started 2007

Rare earths and other rare metals utilized for electronics, automotives, information technologies, and robotics are facing their price increase and tight supply due to the rapid increase of their consumptions and export policies of producing countriespolicies of producing countries.

Project OutlineE t bli h i th l f iti l l t i t i l tEstablish sciences on the roles of critical elements in materials to use alternative elements

R&D Aspects on Research Subjects1. Alternative materials composed of ubiquitous and nonhazardous elements2 Advanced utilization of functions stemming from strategic elements2. Advanced utilization of functions stemming from strategic elements3. Practical material design for the effective use of strategic elements

3

METI also started Rare Metal Substitution Project in 2007

Why Why DyDy??(Nd,Dy)-Fe-B sintered magnets for HV and EV

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Fe BNd,Dy

Operation temperature: 200C Sales of HV

K1(Dy) >> K1(Nd)

Nd2Fe14B

Nd Fe

Dy

High Performance Anisotropic Nanocomposite Permanent Magnets with Low Rare Earth

Elements Science and TechnologyElements Science and Technology

ContentS. Hirosawa, Hitachi Metals., Ltd., Hitachi Metals, NIMS, Ehime Univ., Kitakyushuu Univ.

A new category of permanent magnet materials with no Dy and less Nd with comparable magnetic properties with those of current (Nd,Dy)-Fe-B sintered magnets using HDDR (Hydrogenation-Decomposition-Desorption-Recombination) and Fe-nanocoating processes.

1400

1600

y (k

A/m

)

Nd-Fe-Co-B-Ga / Nd-CuHydrogenation Desorption

1000

1200

Coe

rciv

ity

Nd-Fe-Co-B-Ga

Nd-Fe-Co-B-Ga ModifiedMicrostructural Analyses and Grain-Boundary ModificationNdH2Nd2Fe14B Nd2Fe14B

HydrogenationDecomposition

DesorptionRecombination

2007 2008 2009 2010 2011Year

Fe

Modification

Search of non-

2

Fe2Bα-Fe

Nd2Fe14B Nd2Fe14BNd-rich Nd-rich

Fe-coated CoercivePowder

Metallic Fe Nano-CoatingProcess

Bulk CompositeMagnet

RapidConsolidationProcess

Fe layer

10 μm10 μm

Concept of the Subjects

aqua coating process on hard-magnetic particles

500nm

Process Process

HDDR particleConcept of the Subjects HDDR particle

Rare Metal Substitute Materials Development Rare Metal Substitute Materials Development ProjectProjectDevelopment of technology for reducing Dy usage in Nd-Fe-B magnets

1. Grain Refinement

2. Interfacial Microstructure Control

(2) Intermetallics (3) TDK(2) Yamagata Univ.

SummaryOperation temperature: 200C

PL: S. Sugimoto, Tohoku U.

1. Grain Refinement

Atomization(Hybrid)

(1) SantokuSC

(2) Intermetallics (3) TDK

He JMFinePowder 55

最終目標ﾗｲﾝ(Dy削減30%)

1.0%Dy

30%Dy Saving55

H-HALProcess

5.00 6.00 7.00

(μm

)

Increase in Hc

Dy Saving > 40 %

45

50

0% Dy

MG

Oe）

30

35

40

45

50

(BH)max (MGOe)

基準

中間目標

最終目標

達成値1

達成値2

達成値3基準ﾗｲﾝ

中間目標ﾗｲﾝ(Dy削減20%)

7%Dy

8%Dy

10%Dy

7.7%Dy(29.6kOe)

y(15.4kOe)

2.4%Dy(18.6kOe)

20%Dy Saving

7%Dy

8%Dy

10%Dy0%Dy Saving

15 20 25 30

50

45

40

35

30

(BH) m

ax(M

GO

e)

10

(1) Tohoku Univ.0.00 1.00 2.00 3.00 4.00

0 50 100 150 200

Gra

in s

ize

Alloy powder size (μm)

～1 m

(3) Tohoku Univ

Dy Saving > 20 %30

40

35

10 20 30Hc（kOe）

10% Dy

20%Saving

30%

50%

（BH) m

ax （

M

Nitrogen JM

Helium JM

10 15 20 25 30HcJ (kOe)

15 20 25 30HcJ (kOe)

10(3) Tohoku Univ.

40

50

60

70

80

90

100

Ndの付着率

(%

)

ℓ = 4 mℓ = 3 mℓ = 2 m

Good

Bad

atio

of

Nd-

rich

, P

(%)

P(%

)

1009080

70605040

Existence ProbabilityIn JM

Improvement of SRNd-rich

(4) Tohoku Univ.600 Nd(f) (3) SIST

CF parameter: Negative

c（ ）40

0 1 2 3 4 5

Particle size, d50 /um

Ra

, P 0 1 2 3 4 5Particle size, d50 /m

40Powders

(1) Toyota (1) NIMS High HcThick

G.B. -600

-400

-200

0

200

400 Nd(g)

A20 <r2

>

bulk (001) surface model

at surface inside

(3) SIST

Mag. reversal Grp. of grains

4. Application

120

100

80

60

40

20

0

120100806040200

íÖé•

4

3

2

1

0

120

100

80

60

40

20

0

120100806040200

ñ¢íÖé•

Negative

(2) JAEA

3. Guiding Principles

Development of Hot-dipped Aluminum

Elements Science and Technology: Granted in FY2007Elements Science and Technology: Granted in FY2007

Self-forming Nano-particle Catalyst withoutDevelopment of Hot dipped Aluminum Alloy Coated SteelsT. Tsuru, Tokyo Institute of TechnologySubstitution of Zn with Al on Zn coated steel

Self forming Nano particle Catalyst without Precious Metals Y. Nishihata, Japan Atomic Energy Agency

Substantial reduction and/or

Coating Layer

Chemical Properties of Surface

Corrosion resistivity, Sacrificial ability

Metallography and Reactions in Coated Layer

Intermetallic compounds, Solidified structure

oxidation

reduction

total substitution of the precious metals in the automotive catalyst for gasoline engine

Steel Intermetalliccompounds

Thermodynamics of Interfacial Reactions

Interfacial reactions, Wettability Oxidation

Metallography andStrength of Substrate

Mechanical properties,

固溶・析出ナノリサイクル固溶・析出ナノリサイクル

Solution / precipitation

nano recycle

gasoline engine.

Development of New Hot Dipped Coated Steels

Development of New Hot Dipped Coating Process

Wettability, Oxidation p p ,Adhesion, Structure

y

Development of Barium-based New

Development of TiO2-based Transparent ElectrodeT. Hasegawa, Kanagawa Academy of Science p

Lead-free Piezoelectric Materials with Ultrahigh Piezoelectric Property for Piezoelectric FrontierS Wada Yamanashi University ズ①ズ①ズ①ズ①ズ①ズ①D i t l

and Technology

As an ITO (Indium Tin Oxide) alternative, the sputtering-and CVD (Chemical VaporS. Wada, Yamanashi University シーズ①

ドメインエンジニアリング

シーズ①

ドメインエンジニアリング

分域(ドメイン)制御

化

シーズ①

ドメインエンジニアリング

シーズ①

ドメインエンジニアリング

シーズ①

ドメインエンジニアリング

シーズ①

ドメインエンジニアリング

分域(ドメイン)制御

化

Domain control

ned

Ba-based new Pb-free piezoelectric materials with ultrahigh piezoelectric properties

and CVD (Chemical Vapor Deposition) -based practical processes for fabrication of indium-free TNO (niobium-

微細

微細

refin

O (interstitial sites)

ultrahigh piezoelectric properties for future automobile MEMS applications.

(doped titanium dioxide) transparent conducting thin films will be developed.

Nano-hybridized Precious-metal-free

Elements Science and Technology: Granted in FY2008Elements Science and Technology: Granted in FY2008

Material Design and Processing of Highly- Nano-hybridized Precious-metal-free Catalysts for Chemical Energy ConversionK. Uosaki, Hokkaido University

Material Design and Processing of Highly-dispersed Catalysts with Minimum Precious Metal LoadingsM. Machida, Kumamoto University Nano-hybridized precious-metal-freeNano hybridized precious metal free

catalysts for the innovation of fuel cell and photo-electrochemical cell.

Minimizing the loading of precious metals(PGM=Rh, Pt, Pd) and rare earth elements(Ce) in automotive catalysts by realizingthermally stable and highly dispersed PGM

Dissolution& growth

Adsorption of hetero-metal complex to electrode surface

Precipitation of core ions as metal

Development of Innovative Energy Conversion

thermally stable and highly dispersed PGMnano-particles anchored onto support surface.

t l ti PGM C O

(tonnes) 2002 2006PGM: 30 45 X1.5CeO2: 615 1300 X2.1

JPN demands for autocatalysts

e e op e t o o at e e gy Co e s oSystems with Molecular Catalysts Replacing Precious MetalsY. Naruta, Kyushu UniversityDevelopment of molecular catalysts w/o

catalyticconverter

PGM CeO2

Al2O3 supportAl2O3 support

PGM: ～5 g/viecleCe: 17～20 g/viecle

Ubiquitous Element Strategy for Function EmergenceH. Hosono, Tokyo Institute of Technology

Development of molecular catalysts w/o precious metal ions for water decomposition to H2/O2 as well as O2 reduction using organic-inorganic hybrid systems.

Molecular design

Molecular design

Molecular design

Molecular design

Ca

O

Al

Ca

O

Al

Ca

O

Al

Ca

O

Al

g y yNovel functionality based on abundant elements utilizing built-in nanostructures, interface/surface and/or

High

durabilityLow

overpotentialHigh

selectivityHigh electro-motive force

High

durabilityLow

overpotentialHigh

selectivityHigh electro-motive force

electronelectron

C12A7-Electride

Iron -based superconductor

electronelectron

C12A7-Electride

Iron -based superconductor

interface/surface and/or defects.

Design and Processing of Functional Materials with

Elements Science and Technolgoy: Granted in FY2009Elements Science and Technolgoy: Granted in FY2009

Development of Eco-friendly PostDesign and Processing of Functional Materials with Multi-elements Based on Chemical Potential DiagramsT. Uda, Kyoto University

Chemical Potential DiagramChemical Potential Diagram

Development of Eco-friendly Post Lithium-ion BatteriesS. Okada, Kyushu UniversityReplacement of the rare-metal

Th d l t f

LaPOLaPO

Solid ElectrolytesSolid Electrolytes

g＋

First principle Calculation

g＋

First principle Calculation

・Materials Processing・Chemical Stability・Defect structure・Reaction Mechanism

elements massively used in anode and cathode active materials of lithium-ion battery with economically and ecologically friendly

The development of new phosphate electrolytes for fuel cells, phosphide semiconductorsfor photovoltaic cells, and calcium PO4PO4

Ca

PO4

Ca

PO4 Zn Sn P

Bio MaterialsBio Materials

LaP3O9

LaPO4

Ca5(PO4)3OHPhosphide

SemiconductorsPhosphide

Semiconductors

ZnSnP2

economically and ecologically friendly elements such as sodium and iron.

Opened structure Closed structure

for photovoltaic cells, and calcium hydroxyapatite for bio-materials by computational thermodynamics and the first principle calculations.

Organic Molecular Approach to High-performance Rechargeable Batteries and Mechanistic Elucidation of Charge-discharge Processes

Corner-sharing matrix Edge-sharing matrix Face-sharing matrix

Na 6b siteNa 18e site

Y. Morita, Osaka University

3D NASICON Structure 3D Perovskite Structure 3D Quartz Structure

MO6

octahedra

XO４tetrahedra

Organic molecule high performance rechargeable

3D NASICON Structure 3D Perovskite Structure 3D Quartz Structurebatteries by using the with multi-stage redox ability.

Science and Technology Agency

National National InstiuteInstiute for Materials Science (NIMS)for Materials Science (NIMS)

National Institute for Research in Inorganic Materials (NIRIM)

National Research Institute for Metals (NRIM)

Science and Technology Agency

in Inorganic Materials (NIRIM)(since 1966)

for Metals (NRIM)(since 1956)

Independent Administrative Institution

April 2001 MEXT

National Institute for Materials Science－ The only national lab dedicated to materials science in Japan －

1. Fundamental and inovative research on materials science2. Promotion of widespread use of research results and applications3. Shared use of advanced research facilities4 C l i i f h i h i l i di i li4. Cultivation of researchers in the materials science discipline

Budget : $200 million (subsidy from MEXT$150M)Budget : $200 million (subsidy from MEXT$150M)Personnel : 450 researchers, 100 staffs

500 visiting researchers

Where is NIMS ?

Sengen Site Namiki Site

Sakura Site

11

Organization

NanotechnologiesNanotechnologies Nano System Functionality Center Advanced Nano Characterization Center Computational Materials Science Center Quantum Dot Research Center Quantum Beam Center

Advisory Board

AuditorsPresident

Department of Materials Infrastructure

Nanoscale Materials Nanoscale Materials Center Organic Nanomaterials Center Nano Ceramics Center

Quantum Beam Center

Coordinating

Fellows

Vice PresidentsDepartment of Materials Infrastructure High Voltage Electron Microscopy Station High Magnetic Field Station Beam Line Station Materials Data Sheet Station

M t i l D t b St ti

Materials for Information Technology Advanced Electronics Materials Center Optronics Materials Center Magnetic Materials Center

CoordinatingDirectors Materials Database Station

Materials Manufacturing and Engineering Statio Materials Analysis Station

International Center for Materials

Administration OfficesSecretary’s OfficeAudit Office Magnetic Materials Center

Materials for Biotechnology Biomaterials Center

International Center for YoungScientists（ICYS)

International Center for MaterialsNanoArchitectonics（MANA)

Audit OfficeGeneral Affairs DivisionPlanning Division・Integrated Strategy Office・Research Evaluation Office・International Affairs Office

P bli R l ti Offi

Materials for Environment and Energy High Temperature Materials Center Fuel Cell Materials Center

Doctoral Program in MaterialsScience and Engineering

)

NIMS N t h l S t

・Public Relations Office・Human Resources

Development OfficeCollaboration-promotion OfficeScientific Information OfficePlanning & Research Office

Superconducting Materials Center Photocatalytic Materials Center Structural Metals Center

Materials for Reliability and Safety

NIMS Nanotechnology Support Network

Interdisciplinary ClustersSt t i U f S M t i l

gInformation Technology Office

12

y y Material Reliability Center Composites and Coating Center Sensor Materials Center

Strategic Use of Scarce Materials Social Acceptance of Nanotechnology Corrosion Non-Destructive Evaluation

Topics in energy materials at NIMSTopics in energy materials at NIMS

D f

Doping Eu2+ into Si-Al-O-N structureHigh efficiency & durability due to its structure

Point ofResearch

Si-Al-O-N, High efficiency fluorescent material

Analysis and control of nanostructureImproving coercivity of NdFeB w/o Dy

Point ofResearch

Dy-free permanent magnets

Developed Si-Al-O-N materials

High efficiency & durability due to its structureResearch Improving coercivity of NdFeB w/o DyResearch

Nd-based magnet

Cristal structure of α-Si-Al-O-N Dy is indispensablein high performance permanent magnet

g(Nd10Dy4)Fe80B6

LED ill i ti l

g p p gQuantitative Risk（Rare）+eccentrically-distributed in

China, Country Risk↓Challenge for Dy-free magnet

Analysis and control of nano-structure

Doping Eu2+ into Si-Al-O-N structure↓

Heat resistant and long life

LED illumination lampNd and Cu mapping by 3DAP

Daylight colorDaylight white

Light bulbWhite colorWarm white

Fluorescent in RED, GREEN colors ＋ Blue LED⇒ LED light source with excellent color reproducibility

Mass-produced for backlightOf Liquid crystal TV and cell-

phone 13=20kOe Coercive force=16kOe

Diffusing Nd-Cu Alloy in grain boundary

A new center on Elements Science and Technology A new center on Elements Science and Technology at NIMS from FY2011at NIMS from FY2011

Steel, Mg-alloy, Ti-alloy, Stainless-steel,

Micro-, Nano-, Atomic-scale characterization of materials -

Steel, Mg alloy, Ti alloy, Stainless steel,

Hierarchical control of metallic texturecharacterization of materials -understand roles of alloying elements

Hierarchical control of metallic textureInnovative process techniques to

improve properties

From the Urban Mines

Introducing active atoms into inter-

From the Urban Mines

metallic alloyMorphology control in nano-scale

Mesoporous materials precisely modified pore accuracy

SummarySummary

2005 A feasibility study on the development of Dy-free NdFeB magnets wasapproved by NEDO to a team lead by Sagawa.y y g

TOYOTA started a consortium for Dy free NdFeB magnets in Japan. Later, itwas expanded to four teams from EU.

2007 METI called proposal on Rare Metal Substitute Materials DevelopmentProject, which cover Dy, In, and W.

MEXT called proposals on basic research on Elements Science andMEXT called proposals on basic research on Elements Science andTechnology

2008 TOYOTA funded NIMS-TOYOTA Research Center for Dy-free permanentmagnets and all solid Li-ion battery research.

2010 JST called proposals on Elements Science and Technology as its largegrant scheme CREST and PREST for FY2011grant scheme, CREST and PREST for FY2011.

2011 NIMS will start "Elements Science and Technology Center".

Elements Science and Technology is being recognized as important researchElements Science and Technology is being recognized as important researchdiscipline in Japan getting supports form both MEXT and METI.