Abstract: The present disclosure is directed at methods of preparing rare earth-based permanent magnets having improved coercivity and remanence, the method comprising one or more steps comprising: (a) homogenizing a first population of particles of a first GBM alloy with a second population of particles of a second core alloy to form a composite alloy preform, the first GBM alloy being substantially represented by the formula: ACbRxCoyCudMz, the second core alloy being substantially represented by the formula G2Fe14B, where AC, R, M, G, b, x, y, and z are defined; (b) heating the composite alloy preform particles to form a population of mixed alloy particles; (c) compressing the mixed alloy particles, under a magnetic field of a suitable strength to align the magnetic particles with a common direction of magnetization and inert atmosphere, to form a green body; (d) sintering the green body; and (e) annealing the sintered body.

Abstract: A caster assembly configured to process and store a material includes a reaction chamber, a storage assembly configured to store material processed in the reaction chamber, and a blower configured to process and store the material. The reaction chamber includes a vessel configured to hold the material in a melted state prior to processing and a powder generating assembly configured to receive the material from the melting vessel. The powder generating assembly includes a feeding chamber and a feeding device disposed at least partially within the feeding chamber. The feeding device includes at least one nozzle configured to inject inert fluid, where the fluid is a gas, liquid, or combination of the two into the feeding chamber and a material inlet through which the material is configured to flow into the feeding chamber to be exposed to the inert fluid, where the fluid is a gas, liquid, or combination of the two.

Abstract: The present disclosure is directed at methods of preparing rare earth-based permanent magnets having improved coercivity and remanence, the method comprising one or more steps comprising: (a) homogenizing a first population of particles of a first GBM alloy with a second population of particles of a second core alloy to form a composite alloy preform, the first GBM alloy being substantially represented by the formula: ACbRxCoyCudMz, the second core alloy being substantially represented by the formula G2Fe14B, where AC, R, M, G, b, x, y, and z are defined; (b) heating the composite alloy preform particles to form a population of mixed alloy particles; (c) compressing the mixed alloy particles, under a magnetic field of a suitable strength to align the magnetic particles with a common direction of magnetization and inert atmosphere, to form a green body; (d) sintering the green body; and (e) annealing the sintered body.

Abstract: A caster assembly configured to process and store a material includes a reaction chamber, a storage assembly configured to store material processed in the reaction chamber, and a blower configured to process and store the material. The reaction chamber includes a vessel configured to hold the material in a melted state prior to processing and a powder generating assembly configured to receive the material from the melting vessel. The powder generating assembly includes a feeding chamber and a feeding device disposed at least partially within the feeding chamber. The feeding device includes at least one nozzle configured to inject inert fluid, where the fluid is a gas, liquid, or combination of the two into the feeding chamber and a material inlet through which the material is configured to flow into the feeding chamber to be exposed to the inert fluid, where the fluid is a gas, liquid, or combination of the two.

Abstract: The present disclosure is directed at methods of preparing rare earth-based permanent magnets having improved coercivity and remanence, the method comprising one or more steps comprising: (a) homogenizing a first population of particles of a first GBM alloy with a second population of particles of a second core alloy to form a composite alloy preform, the first GBM alloy being substantially represented by the formula: ACbRxCoyCudMz, the second core alloy being substantially represented by the formula G2Fe14B, where AC, R, M, G, b, x, y, and z are defined; (b) heating the composite alloy preform particles to form a population of mixed alloy particles; (c) compressing the mixed alloy particles, under a magnetic field of a suitable strength to align the magnetic particles with a common direction of magnetization and inert atmosphere, to form a green body; (d) sintering the green body; and (e) annealing the sintered body.

Abstract: This disclosure is directed to sintered bodies comprising grains and a grain boundary composition, wherein: (a) the grains comprise a composition substantially represented by a formula G2M14B, where G is Nd, Dy, Pr, Tb, or a combination thereof, and M is Co, Fe, Ni, or a combination thereof, wherein the grains are optionally doped with one or more rare earth elements; and (b) the grain boundary composition is an alloy composition substantially represented by the formula: Nd8.5-12.5Dy35-45Co32-41Cu3-6.5Fe1.5-5, wherein the subscript values are atom percent relative to the total composition of the the alloy composition.

Abstract: The present disclosure is directed to methods of preparing substantially spherical metallic alloyed particles, having micron and sub-micron (i.e., nanometer)-scaled dimensions, and the powders so prepared, as well as articles derived from these powders. In particular embodiments, these metallic alloyed particles, complising rare earth metals, can be prepared in sizes as small 80 nm in diameter with size variances as low as 2-5%.

Abstract: This disclosure is directed to sintered bodies comprising grains and a grain boundary composition, wherein: (a) the grains comprise a composition substantially represented by a formula G2M14B, where G is Nd, Dy, Pr, Tb, or a combination thereof, and M is Co, Fe, Ni, or a combination thereof, wherein the grains are optionally doped with one or more rare earth elements; and (b) the grain boundary composition is an alloy composition substantially represented by the formula: Nd8.5-12.5Dy35-45Co32-41Cu3-6.5Fe1.5-5, wherein the subscript values are atom percent relative to the total composition of the alloy composition. Corresponding populations of particles are also disclosed.

Abstract: The present disclosure is directed to methods of preparing substantially spherical metallic alloyed particles, having micron and sub-micron (i.e., nanometer)-scaled dimensions, and the powders so prepared, as well as articles derived from these powders. In particular embodiments, these metallic alloyed particles, comprising rare earth metals, can be prepared in sizes as small 80 nm in diameter with size variances as low as 2-5%.

Abstract: A caster assembly configured to process and store a material includes a reaction chamber, a storage assembly configured to store material processed in the reaction chamber, and a blower configured to process and store the material. The reaction chamber includes a vessel configured to hold the material in a melted state prior to processing and a powder generating assembly configured to receive the material from the melting vessel. The powder generating assembly includes a feeding chamber and a feeding device disposed at least partially within the feeding chamber. The feeding device includes at least one nozzle configured to inject inert fluid, where the fluid is a gas, liquid, or combination of the two into the feeding chamber and a material inlet through which the material is configured to flow into the feeding chamber to be exposed to the inert fluid, where the fluid is a gas, liquid, or combination of the two.

Abstract: A caster assembly configured to process and store a material includes a reaction chamber, a storage assembly configured to store material processed in the reaction chamber, and a blower configured to process and store the material. The reaction chamber includes a vessel configured to hold the material in a melted state prior to processing and a powder generating assembly configured to receive the material from the melting vessel. The powder generating assembly includes a feeding chamber and a feeding device disposed at least partially within the feeding chamber. The feeding device includes at least one nozzle configured to inject inert fluid, where the fluid is a gas, liquid, or combination of the two into the feeding chamber and a material inlet through which the material is configured to flow into the feeding chamber to be exposed to the inert fluid, where the fluid is a gas, liquid, or combination of the two.

Abstract: This disclosure is directed to sintered bodies comprising grains and a grain boundary composition, wherein: (a) the grains comprise a composition substantially represented by a formula G2M14B, where G is Nd, Dy, Pr, Tb, or a combination thereof, and M is Co, Fe, Ni, or a combination thereof, wherein the grains are optionally doped with one or more rare earth elements; and (b) the grain boundary composition is an alloy composition substantially represented by the formula: Nd8.5-12.5Dy35-45Co32-41Cu3-6.5Fe1.5-5, wherein the subscript values are atom percent relative to the total composition of the the alloy composition.

Abstract: This disclosure is directed to methods for creating recycled Nd—Fe—B type permanent magnets, the methods comprising homogenizing a first population of particles of a rare earth transitional elemental additive with a second population of particles of a magnetic material, wherein the nature of the rare earth transitional elemental additive and the magnetic material are described herein. Additional steps may include compressing the population of homogenized particles together to form a green body, and heating the green body at a temperature and for a time sufficient to sinter the green body into a sintered body. Compositions resulting from these methods are also within the scope of the disclosure.

Abstract: A caster assembly configured to process and store a material includes a reaction chamber, a storage assembly configured to store material processed in the reaction chamber, and a blower configured to process and store the material. The reaction chamber includes a vessel configured to hold the material in a melted state prior to processing and a powder generating assembly configured to receive the material from the melting vessel. The powder generating assembly includes a feeding chamber and a feeding device disposed at least partially within the feeding chamber. The feeding device includes at least one nozzle configured to inject inert fluid, where the fluid is a gas, liquid, or combination of the two into the feeding chamber and a material inlet through which the material is configured to flow into the feeding chamber to be exposed to the inert fluid, where the fluid is a gas, liquid, or combination of the two.

Abstract: The present disclosure is directed to methods of preparing substantially spherical metallic alloyed particles, having micron and sub-micron (i.e., nanometer)-scaled dimensions, and the powders so prepared, as well as articles derived from these powders. In particular embodiments, these metallic alloyed particles, comprising rare earth metals, can be prepared in sizes as small 80 nm in diameter with size variances as low as 2-5%.

Abstract: The present disclosure is directed at methods of preparing rare earth-based permanent magnets having improved coercivity and remanence, the method comprising one or more steps comprising: (a) homogenizing a first population of particles of a first GBM alloy with a second population of particles of a second core alloy to form a composite alloy preform, the first GBM alloy being substantially represented by the formula: ACbRxCoyCudMz, the second core alloy being substantially represented by the formula G2Fe14B, where AC, R, M, G, b, x, y, and z are defined; (b) heating the composite alloy preform particles to form a population of mixed alloy particles; (c) compressing the mixed alloy particles, under a magnetic field of a suitable strength to align the magnetic particles with a common direction of magnetization and inert atmosphere, to form a green body; (d) sintering the green body; and (e) annealing the sintered body.

Abstract: This disclosure is directed to methods for creating recycled Nd—Fe—B type permanent magnets, the methods comprising homogenizing a first population of particles of a rare earth transitional elemental additive with a second population of particles of a magnetic material, wherein the nature of the rare earth transitional elemental additive and the magnetic material are described herein. Additional steps may include compressing the population of homogenized particles together to form a green body, and heating the green body at a temperature and for a time sufficient to sinter the green body into a sintered body. Compositions resulting from these methods are also within the scope of the disclosure.

Abstract: Methods, systems, and apparatus, including computer programs encoded on computer storage media, for creating magnetic material. One of the methods may make a compound that includes at least one of: i) an amount of Nd in a range of [6.1717, 11.8917] (at. %), inclusive, ii) an amount of Pr in a range of [1.5495, 4.821] (at. %), inclusive, or iii) an amount of Dy in a range of [0.2132, 5.3753] (at. %), inclusive, and an amount of Co in a range of [0, 4.0948] (at. %), inclusive, an amount of Cu in a range of [0.0545, 0.2445] (at. %), inclusive, and an amount of Fe in a range of [81.1749, 85.867] (at. %), inclusive.

Abstract: Methods, systems, and apparatus, including computer programs encoded on computer storage media, for creating magnetic material. One of the methods may make a compound that includes at least one of: i) an amount of Nd in a range of [6.1717, 11.8917] (at. %), inclusive, ii) an amount of Pr in a range of [1.5495, 4.821] (at. %), inclusive, or iii) an amount of Dy in a range of [0.2132, 5.3753] (at. %), inclusive, and an amount of Co in a range of [0, 4.0948] (at. %), inclusive, an amount of Cu in a range of [0.0545, 0.2445] (at. %), inclusive, and an amount of Fe in a range of [81.1749, 85.867] (at. %), inclusive.

Abstract: Methods, systems, and apparatus, including computer programs encoded on computer storage media, for recycling magnetic material to restore or improve the magnetic performance One of the methods includes fragmenting magnetic material to form a powder, mixing the powder with a) a rare earth material R and b) an elemental additive A to produce a homogeneous powder, wherein the rare earth material comprises at least one of: i) Nd, ii) Pr, and iii) Dy, and the elemental additive A comprises at least one of: i) Co, ii) Cu, and iii) Fe, and sintering and magnetizing the homogenous powder to form a Nd—Fe—B magnetic product.