The US is developing rare-earth-free iron nitride magnets for guided projectiles and military equipment.
Niron Magnetics manufactures permanent magnets from iron and nitrogen to reduce the U.S. military's reliance on rare earth elements for modern weapons systems.
The US is entering the testing phase of rare earth-free iron nitride magnet technology for use in guided munitions, drones, and various military systems. This technical solution is expected to help the US military reduce its dependence on external strategic material supply chains.
Scale of production and technology of iron nitride magnets.
Permanent magnets play a crucial role in modern military equipment such as electric motors, sensors, radar, unmanned aerial vehicles (UAVs), and missile guidance systems. However, the strongest magnets currently available primarily use rare earth elements such as neodymium, dysprosium, or terbium, which are heavily influenced by foreign supply chains.
To solve this problem, the American company Niron Magnetics developed iron nitride permanent magnets, which are synthesized primarily from iron and nitrogen. This technology originated from research at the University of Minnesota and received funding from the Advanced Research Projects Agency for Energy (ARPA-E).
Niron's first plant, located in Sartell, Minnesota, has a designed capacity of approximately 1,500 tons of magnets per year and is expected to be operational from 2027. The company also plans to select a location for a second plant with an investment of up to $1.8 billion, with an expected capacity of 10,000 tons per year, aiming for complete domestic manufacturing.
The challenge of reducing dependence on rare earth elements in military equipment.
Rare earth elements are currently present in many critical US military assets such as the F-35 fighter jet, Virginia- and Columbia-class nuclear submarines, Tomahawk cruise missiles, JDAM-guided bombs, and early warning radars. A shortage of these elements could disrupt the weapons production chain.
Iron nitride materials are not intended to completely replace rare earth elements in all military equipment. However, the application of iron-nitride magnets in auxiliary components such as small motors, sensors, or rudder control mechanisms will help save a significant amount of rare earth elements, prioritizing them for essential strategic systems.
Real-world testing on guided missiles and combat equipment.
The Pentagon has begun incorporating the new material into its engineering evaluation program. In 2024, the U.S. Air Force awarded Niron a contract to test the integration of rare-earth-free magnets into UAVs, fighter jet engines, missile guidance systems, and satellites.
By the end of 2025, Niron will partner with Moog Corporation to develop an actuator using iron nitride magnets for guided missiles. This is a key component responsible for converting electrical signals into mechanical motion to control the control fins and adjust the missile's flight path.
Prospects and challenges in field application
If it passes rigorous tests for durability, heat resistance, and vibration in harsh environments, iron nitride magnets would be well-suited for UAVs, smart ammunition, and mass-produced automated equipment. Self-sufficiency in the supply of these small components ensures uninterrupted weapons manufacturing processes in emergency situations.
Overall, iron nitride materials cannot completely replace rare earth magnets in the short term. However, this technology provides the US defense industry with an effective backup option, ensuring continuity in the military equipment supply chain.
