Cost-effective integrated strategy for the fabrication of hard-magnet barium hexaferrite powders from low-grade barite ore

Ultrafine barium hexaferrite（BaFe12O19） powders were synthesized from the metallurgical extracts of low-grade Egyptian barite ore via a co-precipitation route. Hydrometallurgical treatment of barite ore was systematically studied to achieve the maximum dissolution efficiency of Fe（～99.7%） under the optimum conditions. The hexaferrite precursors were obtained by the co-precipitation of BaS produced by the reduction of barite ore with carbon at 1273 K and then dissolved in diluted HCl and FeCl3 solution at pH 10 using NaOH as a base; the product was then annealed at 1273 K in an open atmosphere. The effect of Fe^3＋/Ba^2＋ molar ratio and the addition of hydrogen peroxide（H2O2） on the phase structure, crystallite size, morphology, and magnetic properties were investigated by X-ray diffraction, scanning electron microscopy, and vibrating sample magnetometry. Single-phase BaFe（12）O（19） powder was obtained at an Fe^3＋/Ba^2＋ molar ratio of 8.00. The formed powders exhibited a hexagonal platelet-like structure. Good maximum magnetization（48.3 A×m^2×kg^–1） was achieved in the material prepared at an Fe^3＋/Ba^2＋ molar ratio of 8.0 in the presence of 5% H2O2 as an oxidizer and at 1273 K because of the formation of a uniform, hexagonal-shaped structure.

Process Design for Hybrid Sheet Metal Components

The global trends towards improving fuel efficiency and reducing CO;emissions are the key drivers for lightweight solutions. In sheet metal processing, this can be achieved by the use of materials with a supreme strength-toweight and stiffness-to-weight ratio. Besides monolithic materials such as high-strength or light metals, in particular metal–plastic composite sheets are able to provide outstanding mechanical properties. Thus, the adaption of conventional, wellestablished forming methods for the processing of hybrid sheet metals is a current challenge for the sheet metal working industry. In this work, the planning phase for a conventional sheet metal forming process is studied aiming at the forming of metal–plastic composite sheets. The single process steps like material characterization, FE analysis, tool design and development of robust process parameters are studied in detail and adapted to the specific properties of metal–plastic composites. In material characterization, the model of the hybrid laminate needs to represent not only the mechanical properties of the individual combined materials, but also needs to reflect the behaviour of the interface zone between them.Based on experience, there is a strong dependency on temperature as well as strain rate. While monolithic materials show a moderate anisotropic behaviour, loads on laminates in different directions generate different strain states and completely different failure modes. During the FE analysis, thermo-mechanic and thermo-dynamic effects influence the temperature distribution within tool and work pieces and subsequently the forming behaviour. During try out and production phase,those additional influencing factors are limiting the process window even more and therefore need to be considered for the design of a robust forming process. A roadmap for sheet metal forming adjusted to metal–plastic composites is presented in this paper.