ALOY News & Events

REalloys announced the demonstration of a patent-pending hydrofluoric-acid-free fluorination process for producing metallization-grade rare earth fluorides from rare earth oxides. The innovation expands REalloys' proprietary rare earth metallization technology platform while supporting the development of a scalable North American rare earth supply chain. To validate the performance of the HF-free process, REalloys conducted independent laboratory testing of the resulting rare earth fluoride material. Independent laboratory analysis confirmed the production of fluoride with a final oxygen content of just 0.34 wt%, attributed primarily to surface-absorbed water, a level consistent with rare earth fluoride feedstock used in industrial rare earth metal production. Metallization-grade rare earth fluoride feedstocks typically require oxygen levels below 1 wt%. The results demonstrate that rare earth fluorides suitable for rare earth metal production can be produced without hydrofluoric acid, one of the most hazardous chemicals traditionally used in rare earth processing, enabling a safer and more scalable approach to rare earth metallization. These results demonstrate the ability of REalloys' proprietary process to produce low-oxygen rare earth fluoride intermediates suitable for downstream metallization and alloy production. Hydrofluoric acid is widely considered one of the most hazardous and difficult chemicals used in industrial metallurgy and remains a standard reagent in conventional rare earth fluorination processes widely used in China and other rare earth processing centers. Its extreme toxicity and corrosiveness require specialized containment systems, highly controlled handling procedures, and extensive environmental and regulatory compliance measures. These measures significantly increase operating costs, create substantial safety and environmental risks, and make fluorination using hydrofluoric acid complex and difficult to scale for rare earth processing facilities operating under Western environmental and safety standards. In addition to improving safety, the Company believes that the HF-free process has the potential to reduce operating costs, simplify plant infrastructure, lower environmental and regulatory burdens associated with hydrofluoric acid handling, and support more resilient rare earth processing supply chains. REalloys has filed patent applications covering aspects of the HF-free fluorination chemistry and process design used to produce metallization-grade rare earth fluorides, forming part of the company's broader portfolio of rare earth metallization technologies. Rare earth fluorides are a critical intermediate used in the production of rare earth metals, including dysprosium, terbium, and neodymium, that are essential for high-performance permanent magnets used in F-35 fighter aircraft, missile systems, radar platforms, aerospace systems, electric vehicles, robotics, and advanced computing infrastructure.

REalloys announced plans to build the largest heavy rare earth metallization facility outside of China and the first commercial-scale operation capable of meeting 2027 U.S. defense procurement bans on Chinese sourcing. The equipment for REalloys' heavy rare earth metal facility will be built in Saskatoon in partnership with the Saskatchewan Research Council. Following commissioning and initial test runs, it is anticipated the HREMF equipment will be relocated to Ohio to better serve REalloys' downstream U.S. defense industrial base customers and to supply U.S. Defense Logistics Agency strategic rare earth stockpiles. REalloys will own 100% of the HREMF. The platform will integrate with the company's current metallization operations in Euclid, Ohio, which represent the only heavy rare earth metallization capability currently operating in North America and anchor REalloys' industry-leading rare earth intellectual property portfolio.With initial operations currently targeted for early to mid 2027, and full commercial scale operations currently expected in mid-to-late 2027, the HREMF will represent the first and only commercial-scale heavy rare earth metallization platform with zero-Chinese nexus, coming online as U.S. defense procurement waivers permitting sourcing from non-allied nations expire and statutory restrictions take full effect. In a sector still defined by pilot projects and scale-up risk, this facility aims to resolve the industry's core bottleneck: secure North American metallization of Dysprosium and Terbium for high-performance defense magnets. This builds on the partnership REalloys and SRC first announced in December 2025, which will see REalloys invest in expanded production capacity at SRC's Rare Earth Processing Facility in Saskatoon, SK, in exchange for 80% of the facility's output. Once in full operation, SRC's REPF facility is anticipated to produce high-purity Neodymium-Praseodymium metal and Dy and Tb oxides, which will then be further processed and metallized at REalloys' HREMF.