Abstract: Corrosion-resistant, soft magnetic metal components manufactured by powder metallurgy and infiltration processes are disclosed. The magnetic components are manufactured by a powder metallurgy process using acicular metal particles to form a skeleton, and thermally infiltrating the skeleton.

Abstract: Corrosion-resistant, soft magnetic metal components manufactured by powder metallurgy and infiltration processes are disclosed. The magnetic components are manufactured by a powder metallurgy process using acicular metal particles to form a skeleton, and thermally infiltrating the skeleton.

Abstract: A high density metal component manufactured by powder metallurgy is disclosed. The powder metallurgy method provides metal components having a density greater than 95% of theoretical density using a single sequence of uniaxial pressing and heating. The metal components are manufactured from substantially linear, acicular metal particles having a substantially triangular cross section.

Abstract: A permanent magnet material having the formula, in atomic %:TM.sub.(84.3.-w-z) RE.sub.(3.0+w) B.sub.(12.7+z),wherein -3.3.ltoreq.z<3.3 and -2.0.ltoreq.w<2.0; orTM.sub.(89.8-x-y) RE.sub.(3.5+y) B.sub.(6.7+x),wherein -2.5.ltoreq.y<2.5 and -2.7.ltoreq.x.ltoreq.2.7; orTM.sub.(96.5-q-r) RE.sub.(1+q) B.sub.(2.5+r),wherein -1.5.ltoreq.r.ltoreq.1.5 and 0.ltoreq.q<6.5-r; and wherein TM is a transition metal, RE is a rare earth metal, and B is boron or a combination of boron and carbon. The permanent magnet materials include at least weight percent non-uniaxial material and possess a coercivity of at least 1,000 Oersteds.

Abstract: A method for producing a compacted fully dense permanent magnet by providing a particle charge of a permanent magnet alloy composition from which the article is to be made and placing the charge in a cylindrical container having a generally axially positioned core with the charge surrounding the core within the container. The container and charge are heated to an elevated temperature and extruded to compact the charge to a substantially fully dense permanent magnet article.

Abstract: It has been found that ferromagnetic sheet material can be scribed in order to reduce watt losses by a thermal method involving rapid heating of small areas or narrow bands of the material in a manner that produces sudden thermal expansion to a degree sufficient to produce plastic deformation within the thermally treated zone. This method has been found to be particularly applicable to electrically insulative coated ferromagnetic sheet wherein it has been found that a laser operating in a continuous wave or extended pulse mode can produce the desired deformation in the ferromagnetic material without damage to the coating properties.

Abstract: A method of reducing core losses in a magnetic core characterized by the steps of winding a strip of a previously annealed amorphous magnetic alloy strip into a magnetic core; applying a primary winding onto the magnetic core to establish an AC exciting field in the core; applying a secondary winding onto the core; and applying a DC or a low frequency AC magnetic field to the core at an angle that is non-coincident to the AC exciting field to effect reduced high frequency core losses.

Abstract: A method of consolidating a magnetic core which contains amorphous metal, including the step of thermal spraying an electrically non-conductive material on the edges of the laminations which make up the magnetic core.

Abstract: A transformer utilizing a rotating flux for saturating the entire core. The transformer uses a core configured such that a vector sum of the induction produced by two windings in the core rotates through 360.degree.. This is accomplished by arranging the component induction vectors to be perpendicular and the source voltages associated with each of the component induction vectors to be 90.degree. out of phase. If the inductions are of equal magnitude and the vector sum is sufficient to saturate the core, rotation of the vector sum saturates the entire core and the transformer experiences a very low or nearly negligible hysteresis losses. Various topological configurations for the core, including a toroid, are described. The transformer windings can be arranged for single, two-phase, three-phase, or multi-phase operation.

Abstract: A machine manipulates a laser beam substantially transversely across a moving sheet of flat or curved material. This machine includes a rotating optical system which focuses and moves an elongate beam spot across the moving sheet of flat or curved material, at a high rate of speed. In methods of applying these instruments to produce reductions in watt loss in coated ferromagnetic sheet without damage to the coating, the speed of laser scanning, S.sub.2 (inches/minutes), and the incident power, P (watts), of the beam are selected such that the function, PS.sub.2.sup.-1/2 is between about 0.1 to about 7.

Abstract: Ferromagnetic cores and electric transformers having a ferromagnetic core having at least two ferromagnetic circuits are described. At least one ferromagnetic circuit is composed of a ferromagnetic amorphous material and at least one ferromagnetic circuit is composed of a grain oriented electrical steel. The amorphous material having a saturation induction which is lower than that of the grain oriented steel. Methods of fabricating the core and using the transformer are also described.

Abstract: It has been discovered that a series of grooves in the surface of amorphous magnetic alloy strip can significantly reduce core losses if the grooves are generally transverse to the direction of magnetization. The grooves are between 0.1 and 10.0 of the strip thickness in depth and are preferably on both sides of the strip and spaced about 0.02-2 centimeters apart.

Abstract: A method for making pressed magnetic components having a low core loss characterized by the steps of compacting a plurality of substantially rectangular particles of an oriented iron alloy having a silicon content of from about 2.5% to about 3.5% and a carbon content of up to 0.01% into a compact of predetermined configuration, and stress-relief annealing the compact in a non-oxidizing atmosphere so as to provide a magnetizable compact having low core loss.

Abstract: A method of making pressed magnetic core components having a low core loss property for use in electrical apparatus characterized by reannealing and repressing said components after initial annealing and pressing.

Abstract: A method of making compact cores for use in direct current magnetic apparatus characterized by the steps of severing particles from thin, flat strips of ferrous alloys, said particles being substantially of elongated rectangular shape, annealing said laminations in decarburizing and deoxidizing atmosphere to improve the magnetic characteristics by reducing carbon to less than 0.01% and relieving stresses, compressing the particles into a solidified configuration of the desired core component, and annealing the core component at a temperature upwards of 2200.degree. F. in a non-oxidizing atmosphere to improve the permeability and coercive force values.