Abstract: A compound or complex containing a rare earth element is impinged with a pulsed laser that is so controlled as to photochemically reduce and obtain a rare earth metal (REM). A mixture of REM salts can be impinged using laser light tuned to selectively reduce a particular rare earth-containing salt of the mixture to separate out as its respective rare earth metal.

Abstract: Embodiments of the present invention provide an electromagnet alignment system for AM or 3D printing technology providing improved in-situ alignment of the magnetic particulate material as it is dispensed during deposition to form a 3D shape. In-situ alignment of the magnetic particulate material can be controlled to be unidirectional or multi-directional.

Abstract: A method for producing a bonded permanent magnet by additive manufacturing, comprising: (i) incorporating components of a solid precursor material into at least one deposition head of at least one multi-axis robotic arm of a big area additive manufacturing (BAAM) system, the components of the solid precursor material comprising a thermoplastic polymer and hard magnetic powder; said deposition head performs melting, compounding, and extruding functions; and said BAAM system has an unbounded open-air build space; and (ii) depositing an extrudate of said solid precursor material layer-by-layer from said deposition head until an object constructed of said extrudate is formed, and allowing the extrudate to cool and harden after each deposition, to produce the bonded permanent magnet. The resulting bonded permanent magnet and articles made thereof are also described.

Abstract: An alloy comprising: a magnetostrictive iron alloy having the formula: FexGayAlz, where x is of from about 65 at % to about 90 at %, y is of from about 5 at % to about 35 at %, and z is of from about 0 at % to about 30 at %; and wherein said alloy has a room temperature magnetostriction of at least approximately 150 ppm. An alloy having a saturated magnetostriction of from about at least 150 ppm comprising: a magnetostrictive iron alloy having the formula: FexGayBet, where x is of from about 65 at % to about 90 at %, y is of from about 1 at % to about 35 at %, and t is of from about 1 at % to about 30 at %; and wherein said alloy has a room temperature magnetostriction of at least approximately 150 ppm.

Abstract: A magnetostrictive alloy containing iron and gallium comprising: Fe100?(x+y+z)GaxAlyCz; where x is of from about 5 at. % to about 30 at. %; where x+y is of from about 5 at. % to about 30 at. %; and where z is of from about 0.005 at. % to about 4.1 at. %. The alloys can also contain B and N.

Abstract: A method of applying a Cr-bearing layer to a substrate, comprises introducing an organometallic compound, in vapor or solid powder form entrained in a carrier gas to a plasma of an inductively coupled plasma torch or device to thermally decompose the organometallic compound and contacting the plasma and the substrate to be coated so as to deposit the Cr-bearing layer on the substrate. A metallic Cr, Cr alloy or Cr compound such as chromium oxide, nitride and carbide can be provided on the substrate. Typically, the organometallic compound is introduced to an inductively coupled plasma torch that is disposed in ambient air so to thermally decompose the organometallic compound in the plasma. The plasma is directed at the substrate to deposit the Cr-bearing layer or coating on the substrate.