Rare-earth magnets are extremely brittle and also vulnerable to corrosion, so they are usually plated or coated to protect them from breaking, chipping, or crumbling into powder.
Some countries classify rare earth metals as strategically important,[7] and Chinese export restrictions on these materials have led other countries, including the United States, to initiate research programs to develop strong magnets that do not require rare earth metals.
They are highly resistant to oxidation, but sintered samarium–cobalt magnets are brittle and prone to chipping and cracking and may fracture when subjected to thermal shock.
[17] In 2009, a sudden growth in sales of magnetic desk toys for adults caused a surge in injuries, with emergency room visits estimated at 3,617 in 2012.
[24] After the rule was nullified, the number of ingestion incidents in the country rose sharply, and is estimated to exceed 1,500 in 2019, leading the CPSC to advise children under the age of 14 to not use the magnets.
[17] In 2009 US company Maxfield & Oberton, maker of Buckyballs, decided to repackage sphere magnets and sell them as toys.
[25] Buckyballs launched at New York International Gift Fair in 2009 and sold in the hundreds of thousands before the U.S. Consumer Product Safety Commission issued a recall on packaging labeled 13+.
[28] In the United States, as a result of an estimated 2,900 emergency room visits between 2009 and 2013 due to either "ball-shaped" or "high-powered" magnets, or both, the U.S. Consumer Product Safety Commission (CPSC) has undergone rulemaking to attempt to restrict their sale.
[29] Further investigation by the CPSC published in 2012 found an increasing trend of magnet ingestion incidents in young children and teens since 2009.
Incidents involving older children and teens were unintentional and the result of using the magnets to mimic body piercings such as tongue studs.
Senator Kirsten Gillibrand to U.S. Consumer Product Safety Commission Chairwoman Inez Tenenbaum,[32] the United States Consumer Product Safety Commission filed administrative complaints, attempting to ban the sale of Buckyballs[33] and Zen Magnets.
[37] It was decided by a DC court[38] (CPSC Docket No: 12-2) that "Proper use of Zen Magnets and Neoballs creates no exposure to danger whatsoever.
[49] The European Union's ETN-Demeter project (European Training Network for the Design and Recycling of Rare-Earth Permanent Magnet Motors and Generators in Hybrid and Full Electric Vehicles)[50] is examining sustainable design of electric motors used in vehicles.
The European Union's European Research Council also awarded to Principal Investigator, Prof. Thomas Zemb, and co-Principal Investigator, Dr. Jean-Christophe P. Gabriel, an Advanced Research Grant for the project "Rare Earth Element reCYCling with Low harmful Emissions : REE-CYCLE", which aimed at finding new processes for the recycling of rare earth.
[51] The United States Department of Energy has identified a need to find substitutes for rare-earth metals in permanent-magnet technology and has begun funding such research.