Abstract: A method for producing a sintered rare-earth magnet characterized by sintering a raw material that includes a ribbon-shaped polycrystalline phase with an average grain size of 10 to 200 nm fabricated by rapid solidification of an alloy melt having a rare-earth magnet composition, and a low-melting point phase formed on the surface of the polycrystalline phase and having a melting point lower than the polycrystalline phase.

Abstract: A rare earth magnet, which is represented by a neodymium magnet (Nd2Fe14B) and neodymium magnet films with applications in micro-systems. A method for producing a rare earth magnet, comprising: (a) quenching a molten metal having a rare earth magnet composition to form quenched flakes of nanocrystalline structure; sintering the quenched flakes; subjecting the sintered body obtained to an orientation treatment; and applying a heat treatment with pressurization at a temperature sufficiently high to enable diffusion or fluidization of a grain boundary phase and at the same time, low enough to prevent coarsening of the crystal grains, (b) thick films deposited on a substrate, applying an annealing to crystallize with pressurization at a temperature sufficiently high to enable diffusion or fluidization of a grain boundary phase and, at the same time, low enough to prevent coarsening of the crystal grains.

Abstract: A method of manufacturing a rare earth magnet includes: preparing a powder by preparing a rapidly-solidified ribbon by liquid solidification, and by crushing the rapidly-solidified ribbon; manufacturing a sintered compact by press-forming the powder; and manufacturing a rare earth magnet by performing hot deformation processing on the sintered compact to impart anisotropy to the sintered compact. In this method, the rapidly-solidified ribbon is a plurality of fine crystal grains. The powder includes a RE-Fe—B main phase and a grain boundary phase of a RE-X alloy present around the main phase. RE represents at least one of Nd and Pr. X represents a metal element. A nitrogen content in the powder is adjusted to be at least 1,000 ppm and less than 3,000 ppm by performing at least one of the preparation of the powder and the manufacturing of the sintered compact in a nitrogen atmosphere.

Abstract: A manufacturing method includes: manufacturing a sintered compact having a composition of (Rl)x(Rh)yTzBsMt; manufacturing a precursor by performing hot deformation processing on the sintered compact; and manufacturing a rare earth magnet by performing an aging treatment on the precursor in a temperature range of 450° C. to 700° C. In this method, a main phase thereof is formed of a (RlRh)2T14B phase. A content of a (RlRh)1.1T4B4 phase in a grain boundary phase thereof is more than 0 mass % and 50 mass % or less. Rl represents a light rare earth element. Rh represents a heavy rare earth element. T represents a transition metal. M represents at least one of Ga, Al, Cu, and Co. x, y, z, s, and t are percentages by mass of Rl, Rh, T, B, and M. x, y, z, s, and t are expressed by the following expressions: 27?x?44, 0?y?10, z=100?x?y?s?t, 0.75?s?3.4, 0?t?3.

Abstract: A method includes: manufacturing a sintered compact represented by (Rl)x(Rh)yTzBsMt and has a grain boundary phase; manufacturing a rare earth magnet precursor from the sintered compact; and performing a heat treatment on the rare earth magnet precursor at 450° C. to 700° C. to diffuse and to infiltrate a melt of a modified alloy containing a light rare earth element and either a transition metal element, Al, In, Zn, or Ga into the grain boundary phase. Rl represents a light rare earth element. Rh represents Dy or Tb. T represents a transition metal containing at least one of Fe, Ni, and Co. B represents boron. M represents at Ga, Al, or Cu. x, y, z, s, and t represent mass % of Rl, Rh, T, B, and M. Following expressions are established: 27?x?44, 0?y?10, z=100?x?y?s?t, 0.75?s?3.4, 0?t?3. An infiltration amount of the modified alloy is 0 mass % to 5 mass %.

Abstract: To provide a rare earth magnet ensuring excellent magnetic anisotropy while reducing the amount of Nd, etc., and a manufacturing method thereof. A rare earth magnet comprising a crystal grain having an overall composition of (R2(1-x)R1x)yFe100-y-w-z-vCowBzTMv (wherein R2 is at least one of Nd, Pr, Dy and Tb, R1 is an alloy of at least one or two or more of Ce, La, Gd, Y and Sc, TM is at least one of Ga, Al, Cu, Au, Ag, Zn, In and Mn, 0<x<1, y=12 to 20, z=5.6 to 6.5, w=0 to 8, and v=0 to 2), wherein the average grain size of the crystal grain is 1,000 nm or less, the crystal grain consists of a core and an outer shell, the core has a composition of R1 that is richer than R2, and the outer shell has a composition of R2 that is richer than R1.

Abstract: A method for producing a raw material powder of a permanent magnet, includes: preparing a material powder of a permanent magnet, measuring magnetic characteristics of the material powder, and judging the quality of the material powder as the raw material powder based on a preliminarily determined relation between magnetic characteristics and the structure of the material powder. A method for producing a permanent magnet includes integrating material powders judged as good in the step of judging the quality as raw material powders by the method for producing a raw material powder of a permanent magnet. A method for inspecting a permanent magnet material powder includes transmitting a magnetic field to a material powder of a permanent magnet, receiving the magnetic field from the material powder, and measuring a magnetic field difference between the transmitted magnetic field and the received magnetic field as magnetic characteristics of the material powder.

Abstract: Provided is a manufacturing method of a rare-earth magnet with high coercive force, including a first step of pressing-forming powder as a rare-earth magnet material to form a compact S, the powder including a RE-Fe—B main phase MP (RE: at least one type of Nd and Pr) and a RE-X alloy (X: metal element) grain boundary phase surrounding the main phase; and second step of bringing a modifier alloy M into contact with the compact S or a rare-earth magnet precursor C obtained by hot deformation processing of the compact S, followed by heat treatment to penetrant diffuse melt of the modifier alloy M into the compact S or the rare-earth magnet precursor C to manufacture the rare-earth magnet RM, the modifier alloy including a RE-Y (Y: metal element and not including a heavy rare-earth element) alloy having a eutectic or a RE-rich hyper-eutectic composition.

Abstract: Provided is a manufacturing method of a rare-earth magnet with high coercive force, including a first step of pressing-forming powder as a rare-earth magnet material to form a compact S, the powder including a RE-Fe—B main phase MP (RE: at least one type of Nd and Pr) and a RE-X alloy (X: metal element) grain boundary phase surrounding the main phase; and second step of bringing a modifier alloy M into contact with the compact S or a rare-earth magnet precursor C obtained by hot deformation processing of the compact S, followed by heat treatment to penetrant diffuse melt of the modifier alloy M into the compact S or the rare-earth magnet precursor C to manufacture the rare-earth magnet RM, the modifier alloy including a RE-Y (Y: metal element and not including a heavy rare-earth element) alloy having a eutectic or a RE-rich hyper-eutectic composition.

Abstract: A nanocomposite magnet includes grains including a shell of a Re-TM-B phase and a core of a TM or TM-B phase. Re is a rare earth element, and TM is a transition metal.

Abstract: A rare earth magnet of the invention has a composition represented by the compositional formula RaHbFecCodBeMf, where: R is at least one rare earth element including Y; H is at least one heavy rare earth element from among Dy and Tb; M is at least one element from among Ga, Zn, Si, Al, Nb, Zr, Ni, Cu, Cr, Hf, Mo, P, C, Mg, and V; 13?a?20; 0?b?4; c=100?a?b?d?e?f; 0?d?30; 4?e?20; 0?f?3, and has a structure constituted by a main phase: a (RH)2(FeCo)14B phase, and a grain boundary phase: a (RH)(FeCo)4B4 phase and a RH phase, with a crystal grain size of the main phase of 10 nm to 200 nm.

Abstract: A method for manufacturing a rare-earth magnet, through hot deformation processing, having a high degree of orientation at the entire area thereof and high remanence, without increasing processing cost including a step of press-forming powder as a rare-earth magnetic material to form a compact S; and a step of performing hot deformation processing to the compact S, thus manufacturing the rare-earth magnet C. The hot deformation processing includes two steps of extruding and upsetting. The extruding is to place a compact S in a die Da, and apply pressure to the compact S? in a heated state with an extrusion punch PD so as to reduce the thickness for extrusion to prepare the rare-earth magnet intermediary body S? having a sheet form, and the upsetting is to apply pressure to the rare-earth magnet intermediary body S? in the thickness direction to reduce the thickness, thus manufacturing the rare-earth magnet C.

Abstract: Provided is a method for manufacturing a rare-earth magnet enabling effective penetrant-diffusion of a melt of modifier alloy powder without generating oxidation reaction or hydroxylation reaction when the modifier alloy powder is used for a better coercive force as well.

Abstract: Provided is a method for manufacturing a rare-earth magnet capable of manufacturing a rare-earth magnet with high degree of orientation by sufficient plastic deformation while suppressing cracks at the side faces of a compact that is plastic-deformed during the hot deformation processing. The method includes a step of preparing a compact S, preparing a plastic processing mold including a die D in which a cavity Ca is provided, and punches P that are slidable in the cavity Ca, the cavity Ca having a cross section that is larger in cross-sectional dimensions than a cross section of the compact S that is orthogonal to a pressing direction by the punches P; and a step of placing the compact S in the cavity Ca and performing hot deformation processing, thus manufacturing an orientational magnet C.

Abstract: A method for manufacturing a rare-earth magnet having excellent workability and coercive-force performance in a high-temperature atmosphere and magnetization performance by controlling the content of Pr as the alloy composition to an optimum range, including: press-forming magnetic powder B to form a compact, the magnetic powder B including a RE-Fe-B main phase MP (RE: Nd and Pr) and an RE-X alloy (X: metal element) grain boundary phase BP around the main phase MP having an average grain size of 10 nm to 200 nm; and performing hot deformation processing to the compact to give magnetic anisotropy thereto, thus manufacturing the rare-earth magnet C that is a nano-crystalline magnet. The content of Nd, B, Co and Pr included in the magnetic powder B is Nd: 25 to 35, B: 0.5 to 1.5 and Co: 2 to 7 in terms of at %, and Pr: 0.2 to 5 at % and Fe.

Abstract: A rare-earth sintered magnet including a relatively large main phase, and method for manufacturing same. The rare-earth sintered magnet having excellent coercive-force performance that can be manufactured without using heavy rare-earth elements such as Dy, and including: a RE-T-B main phase C (RE: Nd or Pr, T: Fe or Fe and a part thereof substituted with Co), and a grain boundary phase B surrounding the main phase C, the grain boundary phase including the RE element and the T element. The T element at the grain boundary phase B has density of 60 at % or less, and the grain boundary B has a thickness decreasing from a surface S of the rare-earth sintered magnet M to an inside thereof, and the grain boundary phase B at an area SA of a surface layer of the rare-earth sintered magnet M has an average thickness of 10 nm or more.

Abstract: A method of producing an R-T-B rare earth magnet that include forming an R-T-B (R: rare-earth element, T: Fe, or Fe and partially Co that substitutes for part of Fe) rare earth alloy powder into a compact and performing hot working on the compact, wherein the hot working is performed in a direction that is different from the direction in which the forming was performed.

Abstract: The present invention is a method capable of producing a rare-earth magnet with excellent magnetization and coercivity. The method includes producing a sintered body including a main phase and grain boundary phase and represented by (R11-xR2x)aTMbBcMd (where R1 represents one or more rare-earth elements including Y, R2 represents a rare-earth element different than R1, TM represents transition metal including at least one of Fe, Ni, or Co, B represents boron, M represents at least one of Ti, Ga, Zn, Si, Al, etc., 0.01?x?1, 12?a?20, b=100?a?c?d, 5?c?20, and 0?d?3 (all at %)); applying hot deformation processing to the sintered body to produce a precursor of the magnet; and diffusing/infiltrating melt of a R3-M modifying alloy (rare-earth element where R3 includes R1 and R2) into the grain boundary phase of the precursor.

Abstract: A method of producing an R-T-B rare earth magnet that include forming an R-T-B (R: rare-earth element, T: Fe, or Fe and partially Co that substitutes for part of Fe) rare earth alloy powder into a compact and performing hot working on the compact, wherein the hot working is performed in a direction that is different from the direction in which the forming was performed.

Abstract: A method of manufacturing rare-earth magnets includes, a first step of producing a compact C by subjecting a sintered body S, which is formed of a RE—Fe—B main phase MP having a nanocrystalline structure (where RE is at least one of neodymium and praseodymium) and a grain boundary phase BP of an RE—X alloy (where X is a metal element) located around the main phase, to hot plastic processing that imparts anisotropy; and a second step of producing a rare-earth magnet RM by melting a RE—Y—Z alloy which increases the coercive force of the compact C (where Y is a transition metal element, and Z is a heavy rare-earth element), together with the grain boundary phase BP, and liquid-phase infiltrating the RE—Y—Z alloy melt from a surface of the compact C.