Abstract: The invention involves producing discontinuous, flake-shaped particles of a soft magnetic material, coating the flake-shaped particles with an electrically insulating coating, and consolidating the coated flaked-shaped particles to form a soft magnetic bulk shape. The consolidated bulk shape can comprise a layer or a simple or complex 3D magnet part shape, which has a consolidated layered microstructure that includes laminated soft magnetic regions that are substantially encapsulated by an electrical insulating layer to increase the resistivity of soft magnetic material, especially when used in silicon iron magnet parts.

Abstract: A synthesis process is disclosed for fabrication of mass quantities of high-purity ?-MnBi magnetic powder and subsequent bulk permanent magnet. An illustrative process includes certain steps that include: multiple annealing, multiple comminuting such as multiple ball milling, forming a non-magnetic phase on and/or in the powder particles at particle grain boundaries before particle consolidation such as pressing, and magnetic annealing of a pressed compact. A reproducible and high productive synthesis process is created by combining these steps with other steps, which makes possible production of mass quantities of MnBi powder and bulk magnets with high performance.

Abstract: The present invention provides fine grain structures for rare earth permanent magnets (REPMs) and their production in a manner to significantly enhance flexural strength and fracture toughness of the magnets with no or little sacrifice in the hard magnetic properties. The tough REPMs can have either homogeneous or heterogeneous refined grain microstructural architectures achieved by introducing a small amount of additive particle materials into the magnet matrix, such as fine-sized, insoluble, chemically stable, and non-reactive with the magnet matrix. These additive materials can act effectively as both heterogeneous nuclei sites and grain growth inhibitors during the heat treatment processes, which in turn resulting in refined grain structures of the REPMs. Alternatively, the fine grain structures were also achieved by using magnet alloy feedstock powders with finer particle sizes.

Abstract: The invention involves producing discontinuous, flake-shaped particles of a soft magnetic material, coating the flake-shaped particles with an electrically insulating coating, and consolidating the coated flaked-shaped particles to form a soft magnetic bulk shape. The consolidated bulk shape can comprise a layer or a simple or complex 3D magnet part shape, which has a consolidated layered microstructure that includes laminated soft magnetic regions that are substantially encapsulated by an electrical insulating layer to increase the resistivity of soft magnetic material, especially when used in silicon iron magnet parts.

Abstract: New types of particle feedstocks and heterogeneous grain structures are provided for rare earth permanent magnets (REPMs) and their production in a manner to significantly enhance toughness of the magnet with little or no sacrifice in the hard magnetic properties. The novel tough REPMs made from the feedstock have heterogeneous grain structures, such as bi-modal, tri-modal, multi-modal, laminated, gridded, gradient fine/coarse grain structures, or other microstructural heterogeneity and configurations, without changing the chemical compositions of magnets.

Abstract: New types of particle feedstocks and heterogeneous grain structures are provided for rare earth permanent magnets (REPMs) and their production in a manner to significantly enhance toughness of the magnet with little or no sacrifice in the hard magnetic properties. The novel tough REPMs made from the feedstock have heterogeneous grain structures, such as bi-modal, tri-modal, multi-modal, laminated, gridded, gradient fine/coarse grain structures, or other microstructural heterogeneity and configurations, without changing the chemical compositions of magnets.

Abstract: Magnetic nanoflakes fabricated by surfactant assisted, wet, high energy ball milling of bulk precursors, with or without preceding dry, high energy ball milling, wherein certain nanoflakes indicate hard magnetic properties, crystallographic texture and magnetic anisotropy.

Abstract: RE-TM based permanent magnets (single phase, hybrid, laminated or polymer bonded magnets) fabricated by using nanoflakes produced by surfactant assisted, wet, high energy ball-milling, with or without prior dry high energy ball-milling, where RE represents rare earth elements and TM represents transition metals.

Abstract: Composite RE-TM permanent magnets fabricated by using powders and nanoflakes produced by surfactant-assisted, wet, high energy, ball milling, with or without prior dry, high energy, ball milling; where RE represents rare earth elements and TM represents transition metals and where the powders include Fe nanoparticles, Fe—Co nanoparticles, B2O3, mica, MoS2, CaF2 powders and combinations thereof.

Abstract: Magnetic nanoflakes fabricated by surfactant assisted, wet, high energy ball milling of bulk precursors, with or without preceding dry, high energy ball milling, wherein certain nanoflakes indicate hard magnetic properties, crystallographic texture and magnetic anisotropy.

Abstract: A method for processing CoPt alloys with improved magnetic properties. The method includes sealing a sample of a CoPt alloy in an evacuated quartz tube, and heating the alloy to a temperature of approximately 1000 degrees C. to homogenize the alloy for approximately 3 hours. The sample is then cooled at a controlled cooling rate of 120-150 degrees C. per minute to 600 degrees C. The sample is then held at 600 degrees C. for 10 hours to promote isothermal ordering. Finally, the sample is quenched in mineral oil.

Abstract: A method for processing CoPt alloys with improved magnetic properties. The method includes sealing a sample of a CoPt alloy in an evacuated quartz tube, and heating the alloy to a temperature of approximately 1000 degrees C. to homogenize the alloy for approximately 3 hours. The sample is then cooled at a controlled cooling rate of 120-150 degrees C. per minute to 600 degrees C. The sample is then held at 600 degrees C. for 10 hours to promote isothermal ordering. Finally, the sample is quenched in mineral oil.

Abstract: Nanocrystalline and nanocomposite rare earth permanent magnet materials and methods for making the magnets are provided. The magnet materials can be isotropic or anisotropic and do not have a rare-earth rich phase. The magnet materials comprise nanometer scale grains and possesses a potential high maximum energy product, a high remancence, and a high intrinsic coercivity. The magnet materials having these properties are produced by using methods including magnetic annealing and rapid heat processing.