Less Common Metals (LCM) is expanding its rare earth metal production in the UK to include ferrodysprosium and terbium.

LCM produces alloys and metals required in the production of samarium-cobalt (SmCo) and neodymium-iron-boron (NdFeB) magnets, both high-power rare earth magnets. NdFeB magnets have captured miniaturisation and energy transition technologies as the strongest known permanent magnet material. The spotlight growth trend for NdFeB magnets is in electric vehicles (EVs), where the magnets are used in the drivetrain to improve motor efficiency and optimise battery capacity and vehicle performance.

Neodymium (Nd) and neodymium-praseodymium (NdPr) are the main rare earths in NdFeB magnets, however, can be substituted with other rare earths depending on the application. While less-demanding applications can substitute in lower cost cerium for lower-grade magnets, EV drivetrains and other rotational applications require the addition of higher cost heavy rare earths such as dysprosium (Dy) and terbium (Tb) to improve the coercivity of the magnet, allowing for higher operating temperatures.

As EV markets evolve globally, one of the critical supply chains that need to be addressed is the available sources of high-performance heavy-rare-earth-containing NdFeB magnets, a market currently dominated by China. While rare earth mine supply has ramped up again outside of China since 2017, refining and metal capacity lags and only a handful of magnet projects are in the pipeline. NdFeB magnets are likely to remain a key component of EV drivetrains despite some OEMs looking for substitutes and, as a result, any new magnet capacity targeting the EV market will need to secure a source of both NdPr and Dy/Tb metals and alloys. The addition of Dy and Tb metal and alloys to LCM’s arsenal sets the UK facility up to offer alternative feed for new magnet projects.