Current State of the Art for Applications

ARPA-E Workshop on Rare Earth & Critical Materials

Steven Duclos Chief Scientist Manager, Material Sustainability

GE Global Research Niskayuna, NY

December 6, 2010

1 /7 S. Duclos 2010-12-17

GE Rare Earth Usage

Nd Reveal incandescent lamps Y Thermal barrier coatings for aircraft engines Y, Ce, Tb Gd, Eu, Lu Scintillators for CT & PET imaging Y, Ce, Tb La, Eu Fluorescent lamp phosphors Y Thermal barrier coatings for gas turbines Gd MR contrast agents Industrial motors Generators for 1.5MW+ wind turbines Nd, Dy, Tb Nd, Dy, Tb

Rare Earths Critical to Energy Generation and Use

2 /7 S. Duclos 2010-12-17

GE Criticality Diagram
Higher Re

Impact on GE
Rare Earth Elements

area

Lower Lower Higher

Proportional to spend

Supply and Price Risk

3 /7 S. Duclos 2010-12-17

OEM Technology Options in Addressing Metals Supply Challenges

Sourcing Shorter
Broaden material sources
Volume material buys Diversification Hedging Global sourcing Strategic inventory reserves

Manufacturing

Engineering/R&D

Optimize usage

Longer

Redesig n material

Sort & categorize manufacturing scrap to maximize recycle Use of recycled materials Minimize use of atrisk process materials Near-net shape manufacturing processes

-- Term --

Design for ease of recycling and re-use Material design to minimize at-risk elements Material substitutions System substitution

Each element and each application will use a unique mix of options
4 /7 S. Duclos 2010-12-17

Material Substitution
Rare Earth Reduction 0% 5-20% Strategy Only for highly optimized materials & systems Material composition optimization Recycling (manufacturing yield and end-of-life) Material Substitution System Substitution

20-80% Up to 100%

Multiple Solutions at the Material Level Goal Is To Undertake Technical Programs With A Mix That Results In Significant Reduction
5 /7 S. Duclos 2010-12-17

System Substitution
H Li Na Be Mg Ca Sr Ba Ra Sc Y La Ac Ce Th Pr Pa Nd U Pm Np Sm Eu Pu Gd Tb Dy Cf Ho Es Er Fm Tm Md Yb No Lu Lr Ti Zr Hf Y Cr Mn Fe Ru Os Co Rh Ir Ni Pd Pt Cu Ag Au Zn Cd Hg B Al Ga In Tl C Si Ge Sn Pb N P As Sb Bi 0 S Se Te Po F Cl Br I At He Ne Ar Kr Xe Rn

Incandescent Lamps

K Rb Cs Fr

Nb Mo Tc Ta W Re

Am Cm Bk

Fluorescent Lamps
H Li Na K Rb Cs Fr Be Mg Ca Sr Ba Ra Sc Y La Ac Ce Th Pr Pa Nd U Pm Np Sm Eu Pu Gd Tb Dy Cf Ho Es Er Fm Tm Md Yb No Lu Lr Ti Zr Hf V Cr Mn Fe Ru Os Co Rh Ir Ni Pd Pt Cu Ag Au Zn Cd Hg B Al Ga In Tl C Si Ge Sn Pb N P As Sb Bi 0 S Se Te Po F Cl Br I At He Ne Ar Kr Xe Rn
H Li Na K Rb Cs Fr Be Mg Ca Sr Ba Ra Sc Y La Ac Ce Th Ti Zr Hf

White LEDs
He B Al V Cr Mn Fe Ru Os Co Rh Ir Ni Pd Pt Cu Ag Au Zn Cd Hg Ga In Tl C Si Ge Sn Pb N P As Sb Bi 0 S Se Te Po F Cl Br I At Ne Ar Kr Xe Rn H Li Na K Rb Cs Fr Pr Pa Nd U Pm Np Sm Eu Pu Gd Tb Dy Cf Ho Es Er Fm Tm Md Yb No Lu Lr Be Mg Ca Sr Ba Ra Sc Y La Ac Nb Mo Tc Ta W Re

White OLEDs
He B Al Ti Zr Hf V Cr Mn Fe Ru Os Co Rh Ir Ni Pd Pt Cu Ag Au Zn Cd Hg Ga In Tl C Si Ge Sn Pb N P As Sb Bi 0 S Se Te Po F Cl Br I At Ne Ar Kr Xe Rn Nb Mo Tc Ta W Re

Nb Mo Tc Ta W Re

Ce Th

Pr Pa

Nd U

Pm Np

Sm Eu Pu

Gd

Tb

Dy Cf

Ho Es

Er Fm

Tm Md

Yb No

Lu Lr

Am Cm Bk

Am Cm Bk

Am Cm Bk

Multiple Solutions at the System Level

6 /7 S. Duclos 2010-12-17

Research Approaches
Rare Earths Lighting Recycling of fluorescent lamp phosphors Development of phosphors with reduced RE content LEDs/OLEDs Permanent Magnets / Wind Development of PM recycling approaches Development of PMs with reduced RE content System design solutions Tellurium CdTe solar Develop technology to reduce the CdTe layer thickness

7 /7 S. Duclos 2010-12-17