{"id":20795,"date":"2026-01-07T23:21:11","date_gmt":"2026-01-08T06:21:11","guid":{"rendered":"https:\/\/vpzajoti4c.onrocket.site\/news\/new-phd-research-explores-gap-magnets-to-ease-reliance-on-rare-earth-permanent-magnets\/"},"modified":"2026-01-12T11:38:08","modified_gmt":"2026-01-12T18:38:08","slug":"new-phd-research-explores-gap-magnets-to-ease-reliance-on-rare-earth-permanent-magnets","status":"publish","type":"news-archive","link":"https:\/\/rareearthexchanges.com\/news\/new-phd-research-explores-gap-magnets-to-ease-reliance-on-rare-earth-permanent-magnets\/","title":{"rendered":"New PhD Research Explores \u201cGap Magnets\u201d to Ease Reliance on Rare Earth Permanent Magnets"},"content":{"rendered":"\n<p><strong>Highlights<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>University of Florence PhD demonstrates strontium hexaferrite can be engineered into improved 'gap magnets' that outperform conventional ferrites while avoiding rare earth supply chain risks.<\/li>\n\n\n\n<li>Research achieved high coercivity (up to 0.7 T) and density (92-97%) through nanoparticle synthesis, Al\/Mn doping, and advanced pressing techniques, though performance trade-offs remain.<\/li>\n\n\n\n<li>Recycled ferrite magnets showed commercial-grade properties, offering a practical circular-economy pathway to partially substitute rare earth magnets in moderate-performance motors and components.<\/li>\n<\/ul>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\">\n\n\n\n<p><em>A new PhD thesis by <a href=\"https:\/\/www.linkedin.com\/in\/alessandro-gerace-77a5b1215\/?originalSubdomain=it\" target=\"_blank\" rel=\"noopener noreferrer\" class=\"external-link\">Alessandro Gerace<span class=\"sr-only\"> (opens in a new tab)<\/span><\/a>, completed at the University of Florence (PhD in Chemical Sciences), investigates whether hexagonal ferrites\u2014particularly strontium hexaferrite (SrFe\u2081\u2082O\u2081\u2089, or SrM)\u2014can be engineered into higher-performance permanent magnets capable of partially substituting rare-earth-based magnets in applications that do not require the very highest magnetic strength. <\/em><\/p>\n\n\n\n<p><em>Rather than attempting to replace neodymium-iron-boron (NdFeB) magnets outright, the research focuses on developing so-called \u201cgap magnets\u201d: materials that outperform conventional ferrites while remaining cheaper, more abundant, and less exposed to rare earth supply-chain risk.<\/em><\/p>\n\n\n\n<div class=\"wp-block-rank-math-toc-block\" id=\"rank-math-toc\"><h2>Table of Contents<\/h2><nav><ul><li><a href=\"#how-the-research-was-conducted\">How the Research Was Conducted<\/a><\/li><li><a href=\"#key-findings\">Key Findings<\/a><\/li><li><a href=\"#why-this-matters-for-the-rare-earth-magnet-supply-chain\">Why This Matters for the Rare Earth Magnet Supply Chain<\/a><\/li><li><a href=\"#limitations-and-open-questions\">Limitations and Open Questions<\/a><\/li><li><a href=\"#conclusion\">Conclusion<\/a><\/li><\/ul><\/nav><\/div>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/rareearthexchanges.com\/wp-content\/uploads\/2026\/01\/hexagonal-ferrites-1.jpg\" alt=\"\"><\/figure>\n\n\n\n<p>The motivation is both technical and strategic. Rare-earth magnets underpin electric vehicles, wind turbines, and advanced electronics, but their supply chains\u2014especially processing and magnet manufacturing\u2014are highly concentrated. Gerace\u2019s work asks a pragmatic question: can improved ferrites take over part of the <a class=\"wpil_keyword_link\" href=\"https:\/\/rareearthexchanges.com\/news\/rare-earth-ndfeb-magnet-market-booms-forecast-to-hit-7-8-billion-by-2031\/\" title=\"Rare Earth NdFeB Magnet Market Booms, Forecast to Hit .8 Billion by 2031\" data-wpil-keyword-link=\"linked\" data-wpil-monitor-id=\"94240\">magnet market<\/a>, reserving rare-earth magnets only for applications where their performance is truly indispensable?<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"how-the-research-was-conducted\">How the Research Was Conducted<\/h2>\n\n\n\n<p>The thesis is firmly rooted in materials science and magnet engineering, not policy modeling. Gerace develops and tests a multi-step approach to improving ferrite performance:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Synthesis: Scalable preparation of phase-pure SrM nanoparticles using low-temperature solid-state and modified sol-gel routes.<\/li>\n\n\n\n<li>Doping: Substitution of iron sites with non-rare-earth dopants, particularly aluminum and manganese, to tune coercivity and particle size.<\/li>\n\n\n\n<li>Densification and alignment: Formation of dense magnets using multi-anvil pressing, piston-cylinder pressing, and spark plasma sintering (SPS).<\/li>\n\n\n\n<li>Composite exploration: Experimental hard\u2013soft systems combining SrM with iron nanowires to probe magnetic interactions.<\/li>\n\n\n\n<li>Industrial validation: Assessment of recycled ferrite materials for bonded magnets in collaboration with industry.<\/li>\n<\/ul>\n\n\n\n<p>Throughout, the thesis emphasizes industrial relevance\u2014how materials behave not only in the lab, but when pressed, aligned, and processed at scale<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"key-findings\">Key Findings<\/h2>\n\n\n\n<h3 class=\"wp-block-heading\">1. Improved ferrites are technically achievable.<\/h3>\n\n\n\n<p>The research demonstrates that ferrite properties can be meaningfully tuned through nanoparticle size control, chemical substitution, and alignment during compaction.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">2. Doping boosts resistance to demagnetization\u2014but trade-offs emerge.<\/h3>\n\n\n\n<p>Al- and Mn-doped SrM powders achieved high coercivity values (reported up to ~0.7 T in powder form) and very small particle sizes (around ~40 nm for Mn-doped samples). However, coercivity often declined after densification\u2014a known effect when magnetic grains interact more strongly in bulk magnets.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">3. Very high densities are possible, with consequences.<\/h3>\n\n\n\n<p>Using advanced pressing and SPS, relative densities as high as ~92\u201397% were reported for selected samples. Higher density improved remanence and alignment but tended to reduce coercivity, illustrating the classic performance trade-off in permanent magnet engineering.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">4. Recycled ferrites show near-term promise.<\/h3>\n\n\n\n<p>One of the most practical outcomes is the demonstration that bonded magnets made from recycled ferrite production waste can achieve magnetic properties comparable to commercial ferrite grades, supporting ferrites as a realistic circular-economy material.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"why-this-matters-for-the-rare-earth-magnet-supply-chain\">Why This Matters for the Rare Earth Magnet Supply Chain<\/h2>\n\n\n\n<p>The thesis cites external industry outlooks showing that rare earth processing and magnet manufacturing are far more concentrated than mining, with China holding a dominant position. While this dominance is not Gerace\u2019s original dataset, it provides essential context.<\/p>\n\n\n\n<p>If \u201cgap magnets\u201d can displace even a portion of <a class=\"wpil_keyword_link\" href=\"https:\/\/rareearthexchanges.com\/news\/koreas-analysis-of-the-rare-earth-magnet-struggle-gets-the-structure-right-but-leaves-hard-questions-open\/\" title=\"Korea\u2019s Analysis of the Rare Earth Magnet Struggle Gets the Structure Right-But Leaves Hard Questions Open\" data-wpil-keyword-link=\"linked\" data-wpil-monitor-id=\"73992\">rare-earth magnet<\/a> demand\u2014particularly in moderate-performance motors and components\u2014the result would be reduced pressure on rare-earth processing bottlenecks and greater flexibility for Western manufacturers.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"limitations-and-open-questions\">Limitations and Open Questions<\/h2>\n\n\n\n<p>Gerace does not claim ferrites can replace NdFeB magnets in high-power, space-constrained applications.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Key limitations include:<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Performance ceiling<\/strong>: Even optimized ferrites remain below rare-earth magnets in maximum energy product.<\/li>\n\n\n\n<li><strong>Manufacturing complexity<\/strong>: Preserving coercivity while achieving high density and alignment remains challenging.<\/li>\n\n\n\n<li><strong>Scale-up realism<\/strong>: Some synthesis routes are difficult to scale; industrial trials relied on commercial and recycled powders for volume reasons.<\/li>\n\n\n\n<li><strong>Composite uncertainty<\/strong>: Hard\u2013soft nanocomposites did not demonstrate clear exchange coupling under the tested conditions.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"conclusion\">Conclusion<\/h2>\n\n\n\n<p>This thesis does not promise a rare-earth-free future\u2014but it makes a strong case for strategic substitution. By improving ferrites where performance requirements allow, rare-earth magnets can be reserved for applications that truly need them. In a world of tightening supply chains and rising electrification demand, that distinction matters.<\/p>\n\n\n\n<p><strong>Citation<\/strong>: Gerace, A. <em><a href=\"https:\/\/flore.unifi.it\/bitstream\/2158\/1445218\/1\/PhD%20Thesis%20-%20Alessandro%20Gerace%20-%20XXXVII%20Cycle.pdf\" target=\"_blank\" rel=\"noopener noreferrer\" class=\"external-link\">Improving the Properties of Hexagonal Ferrites for the Replacement of Rare Earth Permanent Magnets<span class=\"sr-only\"> (opens in a new tab)<\/span><\/a><\/em>. PhD Thesis, University of Florence.<\/p>\n\n\n\n<p>\u00a9!-- \/wp:paragraph --&gt;<\/p><span class=\"et_bloom_bottom_trigger\"><\/span>","protected":false},"excerpt":{"rendered":"<p>New PhD research shows hexagonal ferrites can create &#8216;gap magnets&#8217; to reduce rare earth magnet demand in moderate-performance applications.<\/p>\n","protected":false},"author":2,"featured_media":20796,"comment_status":"open","ping_status":"open","template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"news-type":[122,123,128],"organization":[],"regions":[317],"class_list":["post-20795","news-archive","type-news-archive","status-publish","format-standard","has-post-thumbnail","hentry","news-type-ree-news","news-type-clean-energy-technology","news-type-industrial-applications","regions-european-union"],"acf":[],"_links":{"self":[{"href":"https:\/\/rareearthexchanges.com\/wp-json\/wp\/v2\/news-archive\/20795","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/rareearthexchanges.com\/wp-json\/wp\/v2\/news-archive"}],"about":[{"href":"https:\/\/rareearthexchanges.com\/wp-json\/wp\/v2\/types\/news-archive"}],"author":[{"embeddable":true,"href":"https:\/\/rareearthexchanges.com\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/rareearthexchanges.com\/wp-json\/wp\/v2\/comments?post=20795"}],"version-history":[{"count":18,"href":"https:\/\/rareearthexchanges.com\/wp-json\/wp\/v2\/news-archive\/20795\/revisions"}],"predecessor-version":[{"id":73595,"href":"https:\/\/rareearthexchanges.com\/wp-json\/wp\/v2\/news-archive\/20795\/revisions\/73595"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/rareearthexchanges.com\/wp-json\/wp\/v2\/media\/20796"}],"wp:attachment":[{"href":"https:\/\/rareearthexchanges.com\/wp-json\/wp\/v2\/media?parent=20795"}],"wp:term":[{"taxonomy":"news-type","embeddable":true,"href":"https:\/\/rareearthexchanges.com\/wp-json\/wp\/v2\/news-type?post=20795"},{"taxonomy":"organization","embeddable":true,"href":"https:\/\/rareearthexchanges.com\/wp-json\/wp\/v2\/organization?post=20795"},{"taxonomy":"regions","embeddable":true,"href":"https:\/\/rareearthexchanges.com\/wp-json\/wp\/v2\/regions?post=20795"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}