India's Magnetic Revolution:

Pioneering the Path to Self-Reliance

Dr. Nimish Kapoor

Magnetic materials are the backbone of advanced technologies, powering every-thing from electric motors and generators to medical devices, consumer electronics and cell phones. Despite their critical role, India has long depended on imports, risking supply chain disruptions and geopolitical tensions. In the next 25 years, achieving self-reliance in producing these high- per-formance magnets is crucial for India to secure its technological and industrial future. By developing these materials domestically, a dynamic start-up, Ashvini Rare Earth Pvt. Ltd. (AREPL), is ensuring a stable supply, boosting economic resilience and positioning India as a global leader in innovation and manufacturing. This shift is essential for building a robust and self-sufficient nation.

Focused on developing and manufacturing advanced magnetic materials, this start-up is addressing the critical challenge of producing high-performance magnets indigenously.

Shri Vikram Dhoot, MD of the Start-up said "We address the challenges of producing high-performance magnets indigenously, which are crucial for various high-tech applications, including renewable energy, automotive, consumer electronics and more. Our goal is to reduce dependency on imports and strengthen India's position in the global magnet industry". He added, "Our efforts have been further recognised by the Ministry of Mines (MoM), which awarded us a grant of Rs 1.5 crore under the S&T PRISM Scheme. This financial support will significantly accelerate our projects and support our mission to reduce dependency on imports".

Ashvini Magnets uses cutting-edge technologies, including specialised powder manufacturing, injection moulding with abrasive materials and automated quality control. These processes ensure precision and consistency in magnet production.

A Memorandum of Agreement with Bhabha Atomic Research Centre (BARC) and Indian Rare Earths Limited (IREL) aims to produce NdPr metal from Indian resources, boosting India's self-sufficiency in high-performance magnets.

AREPL's partnerships with research institutions like ARCI support the development of advanced Strontium Hexaferrite powders, enhancing magnet technology for various applications, including motors and sensors.

Use-Cases of Magnets Produced by AREPL

Magnetisation technologies with very high currents, above 20,000 amps, are used to create strong and precise magnetic fields. These technologies can produce magnets with many tiny magnetic poles, even in a small space. For example, a magnet with 72 poles can be made on a magnet that is just 50 mm in outer diameter. This allows the magnet to have very detailed and specific magnetic properties, useful in applications like motors, sensors and other high-precision devices.

·       Ferrite powders suitable for Bonded Magnets made from local iron oxides are used to produce magnets.

·       PrNd metal, a metal manufactured from the PrNd oxide which is used in high- per-formance magnets, improving strength and stability for applications in electronics, motors and renewable energy technologies.

·       PrNd fluoride, a compound manufactured from PrNd Oxide and utilised for mass scale manufacturing of PrNd metal.

Positive Impact

Ashvini Magnets has notably advanced various sectors through its innovative products, providing import substitutes, enhancing energy efficiency and reducing carbon footprints. High-performance magnets used in BLDC motors for ceiling fans contribute to energy conservation in line with the National Mission for Enhanced Energy Efficiency. The company has supplied magnets for circuit breakers to GE in Hungary, HVAC motors to Japanese OEMs and for use by leading automotive firms in the USA and Japan.

In the automotive sector, Ashvini Magnets' development of indigenised magnets for dashboards and wheel speed sensors has been highly beneficial. Specially designed magnets for flow meters that eliminate impellers have led to more efficient fluid measurement. In the defence sector, critical magnetic assemblies have been developed to ensure the safety and functionality of essential applications.

Shri Vikram asserts, "Despite fierce competition from Chinese manufacturers and low-cost imports, we have emerged as leaders in India's bonded magnets industry. Our innovations have enabled us to produce previously unavailable products, overcoming challenges and establishing ourselves as industry pioneers."

Opportunities for Youth: The burgeoning Indian magnet market, with an annual requirement of Rs. 2000 crore, presents vast opportunities. As industries adopt advanced technologies reliant on high-performance magnets, there is a significant need for optimised production processes. The magnetic materials sector offers diverse career prospects for electrical and mechanical engineers, electronics and automation experts, power electronics specialists and professionals in powder metallurgy, material science, chemical engineering and polymer science.

Need for Self-Reliance: Shri Ayush emphasises, "Our initiatives are aligned with the Atmanirbhar Bharat initiative, striving to enhance India's self-reliance in key sectors. We are committed to advancing re-search and development, fostering innovation and supporting India's industrial and sustainability goals." By focusing on innovation and quality, Ashvini Magnets aims to significantly impact the industry and contribute to a technologically advanced and self-reliant India.

Idea to Start-up: The Journey

The inspiration for the enterprise emerged in the 1980s from India's reliance on foreign technologies for high-performance magnets. Late Shri Ajit Dhoot sought to address this dependence by founding Ashvini Group to develop and manufacture magnets domestically. Starting in a small garage, Ashvini Group created India's first bonded ferrite magnet in 1988 and later expanded to innovate further.

By 1990, Ashvini Magnets was established to meet rising demand, leading to break-throughs like India's first bonded rare earth magnet in 1994. In 1996, Ashvini Magnets Pvt Ltd marked a significant milestone.

In 2020, Ashvini Rare Earth Pvt. Ltd. (AREPL) was founded to focus on manufacturing rare earth metals and high-performance NdFeB magnets.

AREPL made notable progress by signing agreements with Bhabha Atomic Research Centre (BARC) and Indian Rare Earths Limited (IREL) in 2021. This collaboration aims to produce NdPr metal from Indian oxides. With specialised training in Molten Salt Electrolysis, AREPL is enhancing its manufacturing processes and product quality. The start-up aims to achieve a production capacity of 500 metric tonnes of rare earth metals and 1200 metric tonnes of NdFeB magnets annually, establish a "Mine to Magnet" production process and implement advanced recycling techniques for sustainability.

Mine to Magnet

AREPL aims to master the production process of "Mine to Magnet." The process can be understood in the following points:

Mining: This process is not done by AREPL, but raw materials are procured from IREL (Indian Rare Earths Limited). According to the Government of India, only selected companies have the license to mine these raw materials. IREL specialises in mining, separation and extraction of rare earths in the form of their oxides in a series of steps, ensuring a stable and high-quality supply of raw materials essential for start-up's production process.

Raw Material (Oxide or Fluoride Form) to NdPr Metal: The raw materials in the form of oxides are processed to extract NdPr (Neodymium-Praseodymium) metal through advanced techniques. This involves refining and purifying the raw materials to obtain high-purity NdPr metal, which is a crucial component for high-performance magnets. The process includes steps to ensure the removal of impurities and achieve the desired purity levels.

Metal to Alloy Powder (NdFeB Powders): The NdPr metal is then converted into NdFeB (Neodymium-Iron-Boron) alloy powder. This involves melting the NdPr metal along with iron and boron to form an alloy. The molten alloy is rapidly cooled to produce fine NdFeB powders. These powders are critical for producing magnets with high energy density and excellent magnetic properties. Advanced techniques like strip casting are used to produce uniform and high-quality alloy powders.

Alloy Powders to Magnet Blocks: The alloy powders are processed to form magnet blocks through a series of steps, including pressing and sintering. In the pressing stage, the alloy powders are compacted into the desired shape using presses. The compacted powders are then subjected to high-temperature sintering, which involves heating them in a controlled atmosphere to bond the particles together, resulting in dense and solid magnet blocks with superior magnetic properties.

Cutting Operations on Magnet Blocks for Manufacturing Sintered NdFeB Magnets:

The magnet blocks undergo precise cutting operations to manufacture sintered NdFeB magnets. This involves slicing, grinding and shaping the blocks into the required dimensions and geometries. Advanced machining techniques, such as wire EDM (Electrical Discharge Machining) and precision grinding, are used to ensure the final magnets meet the stringent quality and performance standards required for high-tech applications.

Each stage involves various technologies and techniques to ensure efficiency and quality.

(The author is a science communication specialist. Feedback on this article can be sent to feedback. emplomentnews@gmail.com).

Views expressed are personal.