PASSENGER study demonstrates water-resistant alternatives to rare earth magnets

Every journey toward sustainability begins with a challenge. For magnets, this challenge is creating alternatives to rare earth elements that can withstand real-world conditions. The PASSENGER research team has tackled this by developing and testing new magnets with promising results.

Our recent comprehensive study on manganese-aluminum-carbon (Mn-Al-C) magnets investigated their chemical, physical, and magnetic properties, with a particular focus on corrosion resistance. The tests demonstrated that these innovative magnets maintain remarkable stability during extended water exposure, opening possibilities for transforming applications from water pumps to other aqueous environments.

From challenge to solution

Among the alternatives that do not contain rare earth elements, Mn-Al materials stand out as a particularly promising solution.  What’s truly exciting about these magnets is their environmental footprint. According to the research team, we can produce them with readily available materials using scalable, low-cost manufacturing techniques, while still achieving impressive durability in everyday applications.

“We are essentially creating a middle ground,” explains Dr. Semih Ener from the Technical University of Darmstadt, who led the research. “These magnets have the potential to bridge the gap between basic ferrite magnets and high-performance rare earth magnets, offering a sustainable alternative for many common applications.”

Testing the waters

The team conducted a rigorous four-week testing program using multiple analytical techniques to evaluate the long-term effect of exposure to different environments on the material properties. They exposed the magnets to different aqueous solutions – from regular tap water to specially purified water and selected acidic solutions – and monitored their response. Using specialized equipment and electron microscopy, researchers tracked changes in the magnets’ structural integrity and magnetic properties. The sample magnets, made from manganese and aluminum with small amounts of carbon (Mn-Al-C), showed remarkable stability in regular water conditions during the testing period. This characteristic makes them particularly suitable for applications like water pump motors, electric bikes, and other devices where exposure to moisture is common.

However, the study also revealed some limitations. While the magnets performed well in regular water, they showed vulnerability to saltwater and low pH conditions, with noticeable degradation occurring in these environments. The researchers suggest that additional protective measures, such as specialised coatings, might be necessary for more demanding environments – a challenge they are already working to address.

Why it matters

The timing of this research is particularly relevant as global markets grapple with rare earth element supply chains. Traditional high-performance magnets rely heavily on rare earth elements, primarily sourced from a limited number of countries, leading to price volatility and supply chain vulnerabilities. Europe’s dependency on these materials is particularly acute – the region currently imports nearly 98% of its rare earth magnet needs, making the development of alternatives a strategic priority.

Mind the Gap

The implications of this research extend beyond just technical achievements. As the world moves toward electrification and sustainable energy, the demand for magnets continues to grow. Electric vehicles, wind turbines, and countless everyday devices rely on permanent magnets. Having a middle-range option – a “gap magnet” as researchers call it for use in applications where high-performance is not required – that doesn’t depend on rare earth elements could help diversify the supply chain and reduce environmental impact.

“We are not suggesting these will replace high-performance rare earth magnets in all applications,” the team clarifies. “But for many everyday uses where top-tier performance isn’t critical, these could offer a more balanced, sustainable and affordable alternative.”

The road ahead

While the study results are promising, the research team is already looking to the future. Through the EU-funded PASSENGER project (Pilot Action for Securing a Sustainable European Next Generation of Efficient RE-free magnets) and the RecycleTEAM project, researchers are exploring ways to enhance these magnets’ performance in more challenging environments and bring them from laboratory success to real-world implementation.

Want to be part of this journey?

• Explore detailed findings: Rocabert, U., Parnicki-Krollik, M. A., Maccari, F., Tankov, N., & Ener, S. (2025). Comprehensive Study of τ-Phase Mn–Al–C Magnets: Corrosion Resistance, Structural Integrity, and Magnetic Properties. ACS Omega, 10(1), 683-691. https://doi.org/10.1021/acsomega.4c07540
• Connect with the study’s corresponding author: Semih Ener at semih.ener[at]tu-darmstadt.de
• Recommended reading: PASSENGER factsheet #2: Navigating the EU path in securing Critical Raw Materials (CRMs) for a sustainable future

Acknowledgements

This research was performed within the European Union Horizon 2020 research and innovation programme through the project PASSENGER (Pilot Action for Securing a Sustainable European Next Generation of Efficient RE-free magnets) under grant agreement No 101003914 and the RecycleTEAM project (Project-ID 30EN2056D).

June 2024 has been a busy month for PASSENGER, featuring the biannual consortium meeting as well as the second progress review meeting by the European Commission. The two meetings were held back-to-back in a 2-day hybrid event in Madrid and online, showcasing the project’s achievements in rare earth-free permanent magnets and setting the stage for future developments.  

Day 1: Consortium meeting highlights 

PASSENGER coordinator, Rodolfo Miranda from IMDEA, kicked off the meeting with an overview of the project progress over the past six months, highlighting the milestones reached and the challenges ahead, setting the stage for an engaged discussion between the partners. 

The morning session was dedicated to the progress update from the technical work packages. Partners from Metalpine, MBN, ILPEA and BARLOG discussed the latest progress regarding the development and production scale-up of PASSENGER magnetic loose powders with specific key performance targets. The characterization of the two different magnetic phases of Mn-Al-C (epsilon and tau phase) shows that approximately the 90% value of the target coercivity and remanence have been reached. The target values for PASSENGER improved strontium ferrite were achieved with flying colours, and superior performance was proved compared to commercially available ferrite in terms of coercivity, remanence and compressed density. Subsequent presentations from BARLOG, IMA and TUDA explained the progress in the pilot scale production of permanent magnets, using the loose powders as starting material. The most promising bonded ferrite magnets produced in these pilot plants were tested for certain commercial applications namely traction motors for e-vehicles (e-scooters), gear motors and water pump motors. As summarised by application-WP lead partners from WILO, the experiments showed that it is possible for PASSENGER’s bonded ferrite magnets to replace standard bonded Nd-Fe-B in certain specific applications. In the future, further experimental work is planned to optimize the magnets’ properties and validate their use for such applications, with particular focus on the evaluation of long-term functionality and systematic assessment of key performance properties (e.g. corrosion behaviour and temperature-related operation).  

The afternoon session focused on techno-economic, health and safety assessment, dissemination, exploitation and standardisation updates. ICAMCYL and MNLT explained that PASSENGER magnets cannot only replace conventional REE-based magnets in certain applications, but moreover, they hold significant advantages in terms of increased safety, and lower economic and environmental impact throughout the entire product life compared to Nd-Fe-B. ESF presented the most recent communication and dissemination activities, including participation in high-profile events (e.g. JEMS 2025 and Raw Materials Week 2023) and collaborations with other European projects, notably the set-up of the CRMs4EU cluster, achieving broad project visibility and networking opportunities. The project exploitation plan and IP analysis were also presented to the consortium, including the plans in terms of product standardisation.   

Day 2: European Commission Review 

On 12 June 2024, the PASSENGER team had the opportunity to meet with the project expert reviewer and officers from the European Health and Digital Executive Agency (HaDEA). We shared our achievements in the development of rare earth-free permanent magnets so far, and discussed upcoming challenges, receiving positive feedback and valuable recommendations for the project’s future. 

Next steps 

Looking ahead, the PASSENGER team is set to optimize the properties of our magnets, seek to validate their use in specific applications, and assess their long-term functionality. Stay tuned for more updates!

The PASSENGER partners during the consortium and review meetings in Madrid, Spain, 11-12 June 2024

Sustainable CRMs4EU

In a significant step towards a sustainable and self-reliant future, eight innovative projects, all funded by the European Union, have teamed up to explore how to ensure a resilient and stable supply of critical raw materials (CRMs). These projects, such as DIGIECOQUARRY, INSPIREE, NEW-RE, PASSENGER, REEPRODUCE, REESILIENCE, RESILEX, SALEMA, and concluded ones such as SecREETs and SUSMAGPRO, are crucial for achieving the targets set by the European Union’s Critical Raw Materials Act, which aims to increase strategic autonomy by encouraging domestic production. Whether it’s substituting CRMs with alternative materials, implementing innovative mining systems, or improving the recycling of secondary and end-of-life products, these projects share a common mission: “Making the EU sustainable and self-reliant in the supply of critical raw materials for the green and digital transition“. 

Clustering for Success 

The importance of collaboration and synergies became evident during a meeting in late 2023, where each project brought unique approaches to the table for securing a resilient supply of critical raw materials. Following an internal survey that unveiled numerous collaboration opportunities, representatives of the eight projects gathered again in February 2024, to discuss concrete joint actions on cross-cutting issues, challenges, and opportunities, aiming to maximize the impact of their efforts. 

During the meeting, several main activities of shared interest were identified, including – but not limited to – participating in or organizing joint events, developing joint communication and dissemination activities and crafting policy briefings. The next steps involve the elaboration of a first common clustering activities plan, with PASSENGER initiating efforts to support networking between projects.  

The importance of creating a collaborative ecosystem where EU-funded projects can work together cannot be stressed enough. By combining resources, knowledge, and expertise, these projects can collectively contribute to the overarching goal of making the EU sustainable and self-reliant in critical raw materials.  The diverse strategies and perspectives on applications, spanning materials, technologies, products, and markets, further enhance the value derived from the clustering of these projects.  

The cluster is open to all EU-funded projects dealing with raw materials, exploration, and Earth observation in support of sustainable mining, recycling and substitution of CRMs. If you are part of such a project and are interested in joining our cluster, please contact us at media@esf.org or fill in this introductory form. 

Let’s build a sustainable future together! 

PASSENGER is thrilled to be a part of the 2023 edition of Raw Materials Week, taking place in Brussels from 13-17 November. We are particularly excited to participate in the session titled “Developing the Permanent Magnets Value Chain,” co-organised by SUSMAGPRO project, ERMA and REIA. This session will delve into best practices in smart regulations aimed at establishing a sustainable Circular Economy of rare earths. Topics will include investment in the rare earth magnets value chain, as well as strategies for securing and diversifying the supply of rare earths.

Among the esteemed lineup of speakers, our very own Stefania VITALE, Project Officer at the European Science Foundation, will present PASSENGER’s efforts in substituting Critical Raw Materials in the production of permanent magnets. For further details, you can access the full agenda here.

Raw Materials Week, organised annually by the European Commission, serves as a platform for diverse stakeholders to engage in discussions on raw materials policies and initiatives. It provides an overview of EU activities in this sector, with this year’s focus centering around the European Critical Raw Materials Act. Key topics of discussion include critical and strategic raw materials, strategic projects, investment, permitting, exploration, innovation, circularity, international partnerships, and more. 

What are rare earth-free permanent magnets, and why are they important?

Rare earth-free permanent magnets are magnets that don’t rely on rare-earth elements. They’re crucial because they offer a more sustainable and cost-effective alternative to traditional magnets, which depend on scarce and expensive materials. These magnets can have a significant impact on multiple industries and help address pressing global challenges, such as reducing greenhouse gas emissions and achieving sustainability goals.

What are the PASSENGER prototypes that integrate rare earth-free permanent magnets and what makes them significant?

PASSENGER has successfully developed and tested two prototypes: an e-scooter and a water pump system, using permanent magnets with no content of rare-earths. Both were entirely manufactured in Europe, from the raw materials to the fabrication and product integration.

These prototypes are closely related to two critical sectors for Europe: e-mobility and water management. The project’s focus on these areas aligns with the EU objectives to reduce greenhouse gas emissions and address water-related challenges. This achievement plays a crucial role in PASSENGER, as it actively supports the European Commission’s Critical Raw Materials Act, diminishing our reliance on external sources.

How was the development and production of PASSENGER magnets achieved, and what are their performance characteristics?

These magnets are made from improved strontium ferrite, with no use of critical and more expensive materials (such as cobalt and lanthanum), and based on raw materials widely available in Europe. 

They resulted from collaborative efforts among all project partners. IMDEA Nanociencia (Spain) and ILPEA (Italy) worked together in the development of this improved material along with TU Darmstadt (Germany) and Jožef Stefan Institute (Slovenia). Fabrication of the magnets was carried out by Kolektor (Slovenia) and Ingeniería Magnética Aplicada (Spain). Integration of the magnets in the rotor of the final products was done by WILO (Germany) for the water pump system and by Tizona Motors (Spain) for the e-scooter. Remarkably, in both cases, the motor achieved comparable performance to conventional motors that rely on rare earth-based magnets, in terms of torque, speed, and efficiency. This was possible by working on the optimization of the whole product to exploit the full potential of the novel magnets.

How do rare earth-free permanent magnets work, and what sets them apart?

Rare earth-free permanent magnets offer several advantages over conventional rare earth-based magnets. Firstly, they are more sustainable because they use materials like iron, strontium, manganese, aluminum, which are widely available in Europe and have a lower environmental impact during production. On the contrary, conventional rare-earth elements are frequently monopolized by some countries and they are challenging to extract and refine without producing a significant environmental impact,

Secondly, they are cost-effective, as they do not rely on expensive rare earth elements and do not require additional coatings for corrosion protection, making them more affordable. Rare earth-free magnets are anticipated to be more economically viable than rare earth magnets, particularly as production scales up.

Moreover, these magnets can deliver comparable or even superior performance in various applications due to their higher corrosion resistance and better behavior under increased operation temperatures.

Where can we use rare earth-free permanent magnets today?

The applications are diverse. For example, in water management systems the use of ferrite magnets reduces the carbon footprint. It also makes water pumps more affordable, given that the price of ferrite magnets is significantly inferior to that of rare-earths. In the realm of e-mobility, they can power greener transportation solutions, like e-motorbikes, e-scooters and other components of electric cars. Additionally, rare earth-free permanent magnets can have wide-ranging potential applications in electronics (smartphones, computers) healthcare (medical equipment), and more, all contributing to a greener and more accessible future.

What are the next steps for the PASSENGER project in terms of developing rare earth-free permanent magnets, and what are the challenges that still need to be addressed?

PASSENGER project has already demonstrated the scalability of improved strontium ferrite through the industrial production of several tons of this material, without any increase in the CO₂ footprint in comparison with the production of traditional ferrite (already significantly lower than the CO₂ footprint of rare-earth magnets). The next steps for PASSENGER include reducing the environmental impact in production to the minimum, as well as developing new and improved rare earth-free magnetic materials based on manganese. Additionally, PASSENGER will be testing and validating rare earth-free magnets in a wider range of applications, working closely with research and industry partners.

Challenges still exist in scaling production of novel materials, improving existing materials, and ensuring reliability and durability across various applications. On top of these exciting challenges, PASSENGER’s commitment to sustainable technological advancements, particularly in electromobility, remains steadfast. Effective collaboration among stakeholders will play a crucial role in achieving our goals for the benefit of European citizens.

The PASSENGER project achieves a significant milestone with the successful testing of the prototype integrating rare earth-free permanent magnets. With four tons of magnets produced using raw materials extracted and processed in Europe, the project demonstrates its commitment to greener, European-made solutions.

Prototype of Rare Earth-Free Permanent Magnets Successfully Tested

PASSENGER aims to develop rare-earth-free alternatives to conventional magnets, reshaping industries reliant on magnetic technology and paving the way for a greener and more sustainable future. From pump systems for water management to e-mobility solutions for greener cities, the project holds the potential to transform various sectors. The meeting of the PASSENGER partners, held in Slovenia (31 May – 1 June), showcased remarkable progress towards this direction. Within 24 months since its launch, the EU-funded project, coordinated by IMDEA Nanociencia, has successfully built and tested the prototype that integrates rare earth-free permanent magnets, marking a major breakthrough in sustainable magnetic materials. The project successfully manufactured four tons of powder using raw materials extracted and processed in Europe. The magnets prepared from that powder were then integrated into motors manufactured in Europe, culminating in the assembly of a fully “made-in-Europe” prototype. This achievement aligns with the European Commission’s Critical Raw Materials Act, addressing the continent’s reliance on critical raw materials.

Rotor with PASSENGER’s ferrite material directly molded onto the shaft

Collaborative Strides

Hosted by the Jožef Stefan Institute (JSI), the two-day meeting witnessed dynamic discussions, highlighting the significant strides made in various work packages. The first day of the meeting focused on advances in Manganese-Aluminum-Carbon (MnAlC), exploring different compositions and their influence on the material’s properties, such as its mechanical strength, magnetic behavior, or thermal properties. Partners from LCM, METALPINE, and IMDEA shared their progress in transitioning from casting to powder production. METALPINE and IMDEA also shed light on the next steps in the material’s development, presenting a promising path forward. In parallel, discussions unfolded around precursor production, involving conclusions from LCM, MBN, TUDA, and IMDEA. The compounding phase, spearheaded by BARLOG, was addressed, along with the challenges of hot compaction managed by TUDA and WILO. Day one further explored vital aspects such as sustainability, techno-economic considerations, and health and safety assessments related to raw materials based on the work of ICAMCYL, MNLT and UNE. Dissemination and communication efforts were also discussed extensively, with ESF and ICAMCYL underscoring the importance of sharing project outcomes widely.

Day two of the meeting focused on the advances in hard ferrite magnets, delving into powder precursor materials, with input given by ILPEA, IMDEA and JSI. Compounding and injection-molding aspects were also explored, with insights from BARLOG, KOLEKTOR, and IMA. The integration of PASSENGER’s hard ferrite magnets into various products took center stage during the meeting. Collaborative efforts between WILO, KOLEKTOR, BARLOG, TIZONA, IMA, and OSLV showcased the potential applications in pump systems, e-scooters, e-motorbikes, gear motors, and actuators. CRF provided an update on ongoing evaluations for additional potential applications in electromobility. As the meeting drew to a close, emphasis was placed on the coordination and management of the PASSENGER project. Effective collaboration and seamless communication among stakeholders were highlighted as crucial elements for achieving the project’s goals.

“We are thrilled to celebrate this first prototype by the PASSENGER project, and we are only halfway through,” stated Prof Alberto Bollero, Scientific and Technological Coordinator of PASSENGER. “This achievement underscores the potential of conducting research and innovation within Europe while actively moving towards industrial production. By finding a common language and defining a joint strategy, we can drive sustainable technological advancements that benefit Europe and the world.”

The PASSENGER project continues to advance, with further milestones on the horizon. As the project progresses, it is expected to contribute significantly to the development of sustainable magnetic materials, fostering a more environmentally conscious and resource-efficient future.

For more information about the PASSENGER project and its groundbreaking research, please visit the official website at https://passenger-project.eu.

The PASSENGER partners during the consortium meeting in Ljubljana, Slovenia, 31 May – 1 June 2023

Key points of the proposed Critical Raw Materials Act include

• Setting benchmarks for domestic capacity and diversification of supply
• Developing national programmes for exploring geological resources
• Requiring certain large companies to audit their supply chains through company-level stress tests
• Investing in research, innovation and skills to promote breakthrough technologies in critical raw materials
• Establishing a Raw Materials Academy to promote skills relevant to critical raw material supply chains
• Mitigating environmental impacts, labour rights, human rights and regional stability issues
• Promoting economic development in third countries
• Seeking mutually beneficial partnerships with reliable trading partners to strengthen global supply chains

The regulations align with the EU’s green deal industrial plan and include provisions to establish circularity requirements for permanent magnets. As has been noted, less than 1% of rare earths consumed in the EU are currently recycled. At the same time, permanent magnets are found in a wide variety of products which are strategic for the energy and digital transition, such as wind turbines and electric vehicles. The Act aims to ensure the recyclability of permanent magnets by setting information requirements on theit type and composition.

As a next step, the proposed Regulation will be discussed and agreed upon by the European Parliament and the Council of the European Union before its adoption and entry into force.

Circular economy requirements for Permanent Magnets and PASSENGER’s role in advancing sustainable solutions

In conclusion, the Critical Raw Materials Act is an important step towards securing the supply of critical raw materials in Europe and promoting sustainable and responsible sourcing practices. Implementing this Act can greatly benefit initiatives such as the PASSENGER project, which aims to produce permanent magnets for electromobility without using rare-earth materials – a crucial step towards a sustainable and resource-efficient European economy. By substituting rare-earth permanent magnets with PASSENGER’s magnets in e-scooters, e-bikes, and e-motorbikes, the project is piloting a new approach to electromobility that can increase the availability of sustainable transportation devices while promoting sustainable sourcing of raw materials and responsible manufacturing practices in the EU.

Read more: European Critical Raw Marerials Act (EU press corner)

Critical Raw Materials Act – video animation – © European Union, 2023