Abstract: The present invention relates to highly quenchable Fe-based rare earth magnetic materials that are made by rapid solidification process and exhibit good magnetic properties and thermal stability. More specifically, the invention relates to isotropic Nd—Fe—B type magnetic materials made from a rapid solidification process with a lower optimal wheel speed and a broader optimal wheel speed window than those used in producing conventional magnetic materials. The materials exhibit remanence (Br) and intrinsic coercivity (Hci) values of between 7.0 to 8.5 kG and 6.5 to 9.9 kOe, respectively, at room temperature. The invention also relates to process of making the materials and to bonded magnets made from the magnetic materials, which are suitable for direct replacement of anisotropic sintered ferrites in many applications.

Abstract: The present invention relates to highly quenchable Fe-based rare earth magnetic materials that are made by rapid solidification process and exhibit good magnetic properties and thermal stability. More specifically, the invention relates to isotropic Nd—Fe—B type magnetic materials made from a rapid solidification process with a lower optimal wheel speed and a broader optimal wheel speed window than those used in producing conventional magnetic materials. The materials exhibit remanence (Br) and intrinsic coercivity (Hci) values of between 7.0 to 8.5 kG and 6.5 to 9.9 kOe, respectively, at room temperature. The invention also relates to process of making the materials and to bonded magnets made from the magnetic materials, which are suitable for direct replacement of anisotropic sintered ferrites in many applications.

Abstract: The present invention relates to highly quenchable Fe-based rare earth magnetic materials that are made by rapid solidification process and exhibit good magnetic properties and thermal stability. More specifically, the invention relates to isotropic Nd—Fe—B type magnetic materials made from a rapid solidification process with a lower optimal wheel speed and a broader optimal wheel speed window than those used in producing conventional magnetic materials. The materials exhibit remanence (Br) and intrinsic coercivity (Hci) values of between 7.0 to 8.5 kG and 6.5 to 9.9 kOe, respectively, at room temperature. The invention also relates to process of making the materials and to bonded magnets made from the magnetic materials, which are suitable for direct replacement of anisotropic sintered ferrites in many applications.

Abstract: The present invention relates to highly quenchable Fe-based rare earth magnetic materials that are made by rapid solidification process and exhibit good magnetic properties and thermal stability. More specifically, the invention relates to isotropic Nd—Fe—B type magnetic materials made from a rapid solidification process with a lower optimal wheel speed and a broader optimal wheel speed window than those used in producing conventional magnetic materials. The materials exhibit remanence (Br) and intrinsic coercivity (Hci) values of between 7.0 to 8.5 kG and 6.5 to 9.9 kOe, respectively, at room temperature. The invention also relates to process of making the materials and to bonded magnets made from the magnetic materials, which are suitable for direct replacement of anisotropic sintered ferrites in many applications.

Abstract: The present invention relates to magnetic materials made by rapid solidification processes which exhibit high remanence and intrinsic coercivity values and low flux-aging loss. More specifically, the invention relates to isotropic Nd—Fe—B type materials with remanence and intrinsic coercivity values of greater than 8.0 kG and 10.0 kOe, respectively, at room temperature, and bonded magnets made from the magnetic materials with low flux-aging loss and are suitable for high temperature applications. The invention also relates to methods of making the magnetic materials and the bonded magnets.

Abstract: Carbon addition to the rapidly solidified, preferably melt spun, alloy system of Sm(Co, Fe, Cu, Zr) provides for good isotropic magnetic properties. Importantly, these alloys are nanocomposite in nature and comprise the SmCoC2 phase. Thermal processing of these materials can achieve good magnetic properties at lower temperatures and/or shorter processing times than conventional Sm(Co, Fe, Cu, Zr) powders for bonded magnet application.

Abstract: Manganese-free rare earth-transition metal AB5-type hydrogen-absorbing alloys having favorable high rate discharge characteristics, suitable for use in rechargeable batteries for electrical vehicles or hybrid electrical vehicles, include compositions of the general formula: R(CouAlvMwNi1−u−v−w)z, where R is at least one element selected from rare earth elements and yttrium (Y), M is at least one refractory metal selected from Groups IVB, VB, and VIB of the periodic table, the value of u is from 0 to about 0.25, v is from 0 to about 0.10, w is from 0 to about 0.05, and z, the ratio of R(CouAlvMwNi1−u−v−w)/R, is from about 4.70 to about 5.50. The unit cell volume is from about 87 to about 88.5 A3 at 25° C., the plateau pressure is from about 3 to about 10 apsi at 25° C., and the composition is essentially free of manganese.

Abstract: Magnetic nanocomposite materials including iron, rare earth elements, boron, refractory metals and cobalt which have favorable magnetic properties and are suitable for making bonded magnets are disclosed. Compositions of the present invention can be of the formula: (N1−yLay)vFe100−v−w−x−zCowMzBx, where M is at least one refractory metal selected from Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W; v is from about 5 to about 15; w is greater than or equal to 5; x is from about 9 to about 30; y is from about 0.05 to about 0.5; and z is from about 0.1 to about 5. Preferably M is at least Cr. These materials have good magnetic properties and are suitable for use in preparing bonded magnets.

Abstract: Magnetic nanocomposite materials including iron, rare earth elements, boron, refractory metal and, optionally, cobalt are disclosed. Neodymium and lanthanum are preferred rare earth elements. The amounts of Nd, La, B and refractory metal are controlled in order to produce both hard and soft magnetic phases, as well as a refractory metal boride precipitated phase. The refractory metal boride precipitates serve as grain refiners and substantially improve the magnetic properties of the nanocomposite materials. The materials are particularly suitable for making bonded magnets.

Abstract: A method of forming a magnetically anisotropic powder includes the steps of forming a substantially spherical powder having a major magnetic phase and an average particle size of less than about 200 microns, diffusing hydrogen into the spherical powder at elevated temperatures in an amount sufficient to disproportionate the major magnetic phase, and desorbing the hydrogen by heating the disproportionated powder under vacuum. The magnetic material from which the spherical powder is formed may be a rare earth-transition metal-boron alloy including at least one element from the iron group, at least one rare earth element, and boron. A method of forming a bonded magnet containing magnetically anisotropic particles further includes the steps of mixing the dehydrogenated powder with a binder to form a mixture, and aligning and magnetizing the powder particles in the mixture in a magnetic field.

Abstract: A permanent magnet alloy characterized by increased Curie temperature which is achieved by including nickel and cobalt in combination with at least one rare earth element neodymium and mischmetal in combination with iron and boron. Specifically, the alloy contains, in atomic percent, 10 to 20 mischmetal and/or neodymium, 2 to 30 nickel and/or cobalt, 2 to 14 boron and balance iron.

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: A method for producing a noncircular magnet having asymmetric magnetic properties along axes thereof. A particle charge of composition from which the magnet is to be produced is placed in a container, heated and extruded within the container to compact the particle charge to substantially full density. The particle charge may include at least one rare earth element. The particle charge may be extruded through a noncircular extrusion die, specifically a rectangular die.

Abstract: A permanent magnet alloy consisting essentially of R.sub.2 Fe.sub.14 B, wherein, R is a combination of rare earth elements consisting essentially of, in atomic percent, neodymium 3 to 11 and balance holmium. The alloy may include optional additions of the rare earth elements gadolinium up to 10%, terbium up to 15%, dysprosium up to 16%, erbium up to 18% and thulium up to 12%.

Abstract: A method for producing a fully dense permanent magnet article by placing a particle charge of the desired permanent magnet alloy in a container, sealing the container, heating the container and charge and extruding to achieve a magnet having mechanical anisotropic crystal alignment and full density.

Abstract: A rare-earth element permanent magnet alloy characterized by good magnetic alignment and high energy product, said magnet consisting essentially of, in atomic percent, at least one rare earth element didymium, mischmetal, neodymium and thorium 12 to 20, boron 4 to 14 and balance iron.

Abstract: A rare-earth element permanent magnet alloy characterized by good magnetic alignment and high energy product, said magnet consisting essentially of, in atomic percent, at least one rare earth element didymium, mischmetal, neodymium and thorium 12 to 20, boron 4 to 14 and balance iron.

Abstract: A plurality of relatively high magnetic permeability strips are interleaved to form layers of a closed loop differential transformer core. Although the material of each layer by itself may have a relatively square hysteresis loop, the core formed of a plurality of interleaved layers of such material has a substantially more rounded hysteresis loop. Such a core can advantageously be used in a ground fault interruption circuit in which power leads pass through a central opening in the core to form a primary winding and a secondary winding wound on the core may have a capacitor connected in circuit therewith to complete a resonant circuit.