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: Recycled Nd—Fe—B sintered magnets. One of the recycled Nd—Fe—B sintered magnets includes a composition of WaRbAc, where waste material W comprises material from a waste Nd—Fe—B sintered magnet, rare earth material R comprises at least one of: Nd or Pr, and elemental additives A comprises at least one of: Nd, Pr, Dy, Co, Cu, or Fe, and indices a, b, and c indicate atomic percentages of the corresponding compositions or elements and the atomic percentages of the rare earth material R and the elemental additives A have values satisfying Nd[0.1-19 at. %*s(Nd), x]Pr[0.1-19 at. %*s(Pr), y]Dy[0.1-19 at. %*s(Dy), z]Co[0 at. %, d]Cu[0 at. %, e]Fe[0 at. %, f] where [m,n] means a range from minimum m and maximum n, s(t) is the atomic percent of element t in starting composition, x=18 at. %-[81,99.9] at. %*(s(Nd)+s(Pr)+s(Dy)), y=18 at. %-[81,99.9] at. %*(s(Nd)+s(Pr)+s(Dy)), z=18 at. %-[81,99.9] at. %*(s(Nd)+s(Pr)+s(Dy)), d=3 at. %-[81,99.9] at. %*s(Co), e=0.3 at. %-[81,99.9] at. %*s(Cu), and f=77 at. %-[81,99.9] at.

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 demagnetizing magnetic material from a waste magnet assembly by cyclic heating and cooling of the magnetic material, fragmenting adhesives attached to the magnetic material, cracking coating layers of the magnetic material, and subjecting the magnetic material to at least one of: a) a mechanical treatment or b) a chemical treatment, to remove the coating layers and prepare the magnetic material without impurities, fragmenting the demagnetized magnetic material to form a powder, and mixing the powder with a rare earth material R and an elemental additive A to produce a homogeneous powder, wherein the rare earth material R comprises at least one of: Nd or Pr, and the elemental additive A comprises at least one of: Nd, Pr, Dy, Co, Cu, and Fe.