Abstract: A permanent magnet alloy having at least one light rare earth element, iron and carbon. The alloy has a cellular microstructure of at least two solid phases with a Fe.sub.14 R.sub.2 C.sub.1 magnetically hard, tetragonal major phase surrounded by at least one minor phase. The light rare earth element may be Pr or Nd. At least one heavy rare earth element, such as Dy, may be used. Boron may be included in the alloy. The alloy is produced by casting and heating to form the Fe.sub.14 R.sub.2 (C,B).sub.1 magnetically hard, tetragonal major phase.

Abstract: A method of producing high performance permanent magnets is disclosed in which particles of a master alloy consisting of Fe.sub.2 B having a maximum particle size of 50 microns is admixed with Fe powder and particles of a rare earth capable of combining with Fe and B to form a tetragonal compound of Fe.sub.14 R.sub.2 B type. The admixture is compacted and a magnetic material is formed of the master alloy, Fe powder and rate earth particles which includes a major phase of at least one intermetallic compound of the Fe-R-B type having a crystal structure of the substantially tetragonal system and while the particle size of the crystal structure is controlled by sintering the compacted admixture at a temperature of about 700.degree. C. to 1000.degree. C. for from a fraction of an hour to 36 hours. The magnetic material is then annealed at a temperature of about 550.degree. C. to 650.degree. C. for a fraction of an hour to 2 hours.

Abstract: A method of producing .Iadd.permanent magnet material for .Iaddend.high performance permanent magnets is disclosed in which particles of a master alloy consisting of Fe.sub.2 B having a maximum particle size of 50 microns is admixed with Fe powder and particles of a rare earth capable of combining with Fe and B to form a tetragonal compound of Fe.sub.14 R.sub.2 B type. The admixture is compacted and a magnetic material is formed of the master alloy, Fe powder and .[.rate.]. .Iadd.rare .Iaddend.earth particles which includes a major phase of at least one intermetallic compound of the Fe-R-B type having a crystal structure of the substantially tetragonal system and while the particle size of the crystal structure is controlled by sintering the compacted admixture at a temperature of about 700.degree. C. to 1000.degree. C. for from a fraction of an hour to 36 hours. The magnetic material is then annealed at a temperature of about 550.degree. C. to 650.degree. C. for a fraction of an hour to 2 hours.