Abstract: A soft magnetic alloy having a good combination of formability and magnetic properties is disclosed. The alloy has the formula Fe100-a-b-c-d-e-fSiaMbLcM?dM?eRf wherein M is Cr and/or Mo; L is Co and/or Ni; M? is one or more of Al, Mn, Cu, Ge, Ga; M? is one or more of Ti, V, Hf, Nb, W; and R is one or more of B, Zr, Mg, P, Ce. The elements Si, M, L, M?, M?, and R have the following ranges in weight percent: Si ??4-7 M 0.1-7 L 0.1-10 M? up to 7 M? up to 7 R up to 1 The balance of the alloy is iron and usual impurities. A thin-gauge article made from the alloy and a method of making the thin-gauge article are also disclosed.

Abstract: A magnetic iron alloy and process of making the same. The alloy includes iron, approximately 2 wt. % to approximately 8 wt. % cobalt, approximately 0.05 wt. % to approximately 5 wt. % manganese, and approximately 0.05 wt. % to approximately 5 wt. % silicon. The alloy may also include up to approximately 0.3 wt. % chromium, up to approximately 2 wt. % vanadium, up to approximately 1 wt. % nickel, up to approximately 0.05 wt. % niobium, and up to approximately 0.02 wt. % carbon.

Abstract: An Fe-base, soft magnetic alloy is disclosed. The alloy has the general formula Fe100-a-b-c-d-x-y MaM?bM?cM??d Px Mny where M is Co and/or Ni, M? is one or more of Zr, Nb, Cr, Mo, Hf, Sc, Ti, V, W, and Ta, M? is one or more of B, C, Si, and Al, and M?? is selected from the group consisting of Cu, Pt, Ir, Zn, Au, and Ag. The subscripts a, b, c, d, x, and y represent the atomic proportions of the elements and have the following atomic percent ranges: 0?a?10, 0?b?7, 5?c?20, 0?d?5, 0.1?x?15, and 0.1?y?5. The balance of the alloy is iron and usual impurities. Alloy powder, a magnetic article made therefrom, and an amorphous metal article made from the alloy are also disclosed.

Abstract: A powder including a plurality of particulates, each particulate including a soft magnetic metallic core coated with a continuous dielectric coating having a thickness selected from a range of 100 nanometers to 100 micrometers. The particulates have a mean particle size selected from a range of 100 nanometers to 250 micrometers. Methods for forming the powder are disclosed. A soft magnetic composite component includes a soft magnetic material in a dielectric matrix, wherein (i) the soft magnetic material comprises a plurality of particulates comprising metallic cores, (ii) each metallic core is coated by a continuous dielectric coating covering >90% of a surface area of the metallic core, (iii) the metallic cores are electrically isolated from each other, and (iv) the dielectric coatings of adjacent metallic cores are consolidated together. Methods for formation of the soft magnetic component by additive manufacturing and hot isostatic pressing are disclosed.

Abstract: A bonded soft magnet object comprising bonded soft magnetic particles of an iron-containing alloy having a soft magnet characteristic, wherein the bonded soft magnetic particles have a particle size of at least 200 nm and up to 100 microns. Also described herein is a method for producing the bonded soft magnet by indirect additive manufacturing (IAM), such as by: (i) producing a soft magnet preform by bonding soft magnetic particles with an organic binder, wherein the magnetic particles have an iron-containing alloy composition with a soft magnet characteristic, and wherein the particles of the soft magnet material have a particle size of at least 200 nm and up to 100 microns; (ii) subjecting the preform to an elevated temperature sufficient to remove the organic binder to produce a binder-free preform; and (iii) sintering the binder-free preform at a further elevated temperature to produce the bonded soft magnet.

Abstract: A magnetic iron alloy and process of making the same. The alloy includes iron, approximately 2 wt. % to approximately 8 wt. % cobalt, approximately 0.05 wt. % to approximately 5 wt. % manganese, and approximately 0.05 wt. % to approximately 5 wt. % silicon. The alloy may also include up to approximately 0.3 wt. % chromium, up to approximately 2 wt. % vanadium, up to approximately 1 wt. % nickel, up to approximately 0.05 wt. % niobium, and up to approximately 0.02 wt. % carbon.

Abstract: A soft magnetic alloy having a good combination of formability and magnetic properties is disclosed. The alloy has the formula Fe100-a-b-c-d-e-fSiaMbLcM?dM?eRf wherein M is Cr and/or Mo; L is Co and/or Ni; M? is one or more of Al, Mn, Cu, Ge, Ga; M? is one or more of Ti, V, Hf, Nb, W; and R is one or more of B, Zr, Mg, P, Ce. The elements Si, M, L, M?, M?, and R have the following ranges in weight percent: Si ?4-7 M 0.1-7? L 0.1-10 M? up to 7 M? up to 7 R up to 1 The balance of the alloy is iron and usual impurities. A thin-gauge article made from the alloy and a method of making the thin-gauge article are also disclosed.

Abstract: An Fe-base, soft magnetic alloy is disclosed. The alloy has the general formula Fe100 a-b-c-d-x-y MaM?bM?cM??dPxMny where M is Co and/or Ni, M? is one or more of Zr, Nb, Cr, Mo, Hf, Sc, Ti, V, W, and Ta, M? is one or more of B, C, Si, and Al, and M?' is selected from the group consisting of Cu, Pt, Ir, Zn, Au, and Ag. The subscripts a, b, c, d, x, and y represent the atomic proportions of the elements and have the following atomic percent ranges: 0?a?10, 0?b?7, 5?c?20, 0?d?5, 0.1?x?15, and 0.1?y?5. The balance of the alloy is iron and usual impurities. Alloy powder, a magnetic article made therefrom, and an amorphous metal article made from the alloy are also disclosed.

Abstract: Methods of manufacturing laminated, rare earth, permanent magnets with dielectric layers having increased electrical resistivity and improved mechanical strength suitable for use in high performance, rotating machines comprising sequentially laminating permanent magnet layers with transition and/or diffusion reaction layers; wherein the transition and/or diffusion reaction layers surround sulfide-based dielectric layers, thereby avoiding direct contact between the dielectric layers with permanent magnet layers.

Abstract: Laminated, rare earth, permanent magnets with one or more dielectric layers, suitable for use in high performance, rotating machines comprising: sequential laminates of permanent magnet layers and dielectric layers separated by transition and/or diffusion reaction layers, where said sequentially laminated magnets indicate increased electrical resistivity with improved mechanical strength.

Abstract: Laminated, mechanically strong, rare earth, permanent magnets with dielectric layers having increased electrical resistivity and improved mechanical strength suitable for use in high performance, rotating machines comprising sequential laminates of permanent magnet layers and transition and/or diffusion reaction layers; wherein the transition and/or diffusion reaction layers surround sulfide-based dielectric layers, thereby avoiding direct contact between the dielectric layers with permanent magnet layers.

Abstract: Methods of manufacturing laminated, rare earth, permanent magnets with dielectric layers having increased electrical resistivity and improved mechanical strength suitable for use in high performance, rotating machines comprising sequentially laminating permanent magnet layers with transition and/or diffusion reaction layers; wherein the transition and/or diffusion reaction layers surround sulfide-based dielectric layers, thereby avoiding direct contact between the dielectric layers with permanent magnet layers.