Abstract: An iron-based rare earth boron-based isotropic magnet alloy, which has an alloy composition represented by T100-x-y-z(B1-nCn)xREyMz (where T is a transition metal element containing at least Fe, RE contains at least Nd, and M is one or more metal elements selected from the group consisting of Al, Si, V, Cr, Ti, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au, and Pb), 4.2 atom %?x?5.6 atom %, 11.5 atom %?y?13.0 atom %, 0.0 atom %?z?5.0 atom %, and 0.0?n?0.5, and the iron-based rare earth boron-based isotropic magnet alloy has an average crystal grain size of 10 nm to less than 70 nm as a main phase.

Abstract: A method for producing a rare-earth alloy based binderless magnet according to the present invention includes the steps of: (A) providing a rapidly solidified rare-earth alloy magnetic powder; and (B) compressing and compacting the rapidly solidified rare-earth alloy magnetic powder by a cold process without using a resin binder, thereby obtaining a compressed compact, 70 vol % to 95 vol % of which is the rapidly solidified rare-earth alloy magnetic powder.

Abstract: The iron-based rare-earth nanocomposite magnet of the present invention has a composition T100?x?y?z?nQxRyTizMn, where T is Fe or a transition metal element in which Fe is partially replaced by Co and/or Ni; Q is B and/or C; R is at least one rare-earth element including substantially no La or Ce; and M is at least one metal element selected from Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb. x, y, z and n satisfy 5?x?10 at %, 7?y?10 at %, 0.1?z?5 at % and 0?n?10 at %, respectively. The magnet includes R2Fe14B-type compound phases and ? —Fe phases forming a magnetically coupled nanocomposite magnet structure. The R2Fe14B-type compound phases have an average crystal grain size of 30 nm to 300 nm and the ? —Fe phases have an average crystal grain size of 1 nm to 20 nm. The magnet has magnetic properties including a coercivity of at least 400 kA/m and a remanence of at least 0.9 T.

Abstract: A method of making a magnetic alloy material includes the steps of: preparing a melt of an alloy material having a predetermined composition; rapidly cooling and solidifying the melt to obtain a rapidly solidified alloy represented by: Fe100-a-b-cREaAbTMc where RE is at least one rare-earth element selected from La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er and Tm and including at least about 90 at % of La; A is at least one element selected from Al, Si, Ga, Ge and Sn; TM is at least one transition metal element selected from Sc, Ti, V, Cr, Mn, Co, Ni, Cu and Zn; and 5 at %?a?10 at %, 4.7 at %?b?18 at % and 0 at %?c?9 at %; and producing a compound phase having an NaZn13-type crystal structure in at least about 70 vol % of the rapidly solidified alloy.

Abstract: The iron-based rare-earth nanocomposite magnet of the present invention has a composition T100-x-y-z-nQxRyTizMn, where T is Fe or a transition metal element in which Fe is partially replaced by Co and/or Ni; Q is B and/or C; R is at least one rare-earth element including substantially no La or Ce; and M is at least one metal element selected from Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb. x, y, z and n satisfy 5?x?10 at %, 7?y?10 at %, 0.1?z?5 at % and 0?n?10 at %, respectively. The magnet includes R2Fe14B-type compound phases and ? —Fe phases forming a magnetically coupled nanocomposite magnet structure. The R2Fe14B-type compound phases have an average crystal grain size of 30 nm to 300 nm and the ? —Fe phases have an average crystal grain size of 1 nm to 20 nm. The magnet has magnetic properties including a coercivity of at least 400 kA/m and a remanence of at least 0.9 T.

Abstract: To make a raw alloy, consisting mostly of amorphous structure, highly productively and at a reduced cost for a nanocomposite magnet, a molten alloy represented by Fe100-x-y-zRxQyMz (where R is at least one element selected from Pr, Nd, Dy and Tb; Q is B and/or C; M is at least one element selected from Co, Al, Si, Ti, V, Cr, Mn, Ni, Cu, Ga, Zr, Nb, Mo, Ag, Pt, Au and Pb; and 1 at %?x<6 at %, 15 at %?y?30 at % and 0 at %?z?7 at %) is prepared. This molten alloy is rapidly cooled by a strip casting process in which the alloy is fed onto a chill roller, rotating at a peripheral velocity of 3 m/s to less than 20 m/s, at a feeding rate per unit contact width of 0.2 kg/min/cm to 5.2 kg/min/cm. In this manner, an alloy including at least 60 volume percent of amorphous phase can be obtained.

Abstract: An iron-based rare-earth nanocomposite magnet according to the present invention includes an Nd2Fe14B phase and an ?-Fe phase and has a composition represented by the compositional formula: T100-x-y-z-n(B1-qCq)xRyTizMn, where T is at least one transition metal element selected from the group consisting of Fe, Co and Ni and always including Fe, R is at least one rare-earth element including substantially no La or Ce, and M is at least one metal element selected from the group consisting of Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb, and the mole fractions x, y, z, n and q satisfy the inequalities of: 4 at %?x?10 at %, 6 at %?y?10 at %, 0.05 at %?z?5 at %, 0 at %?n?10 at %, and 0.05?q?0.5, respectively. The magnet includes 5 vol % to 60 vol % of ?-Fe phase with an average crystal grain size of 1 nm to 50 nm and 40 vol % to 90 vol % of Nd2Fe14B phase with an average crystal grain size of 5 nm to 100 nm.

Abstract: A method for producing a rare-earth alloy based binderless magnet according to the present invention includes the steps of: (A) providing a rapidly solidified rare-earth alloy magnetic powder; and (B) compressing and compacting the rapidly solidified rare-earth alloy magnetic powder by a cold process without using a resin binder, thereby obtaining a compressed compact, 70 vol % to 95 vol % of which is the rapidly solidified rare-earth alloy magnetic powder.

Abstract: A rare-earth alloy powder is obtained by rapidly cooling a melt of an alloy by an atomization process. The alloy has a composition represented by (Fe1-mTm)100-x-y-zQxRyTizMn, where T is at least one of Co and Ni, Q is at least one of B and C, R is at least one of the rare-earth metal elements and yttrium, and M is at least one of Nb, Zr, Mo, Ta and Hf. The mole fractions x, y, z, m and n satisfy 10 at %<x?25 at %, 6 at %?y<10 at %, 0.1 at %?z?12 at %, 0?m?0.5, and 0 at %?n?10 at %, respectively. By adding Ti to the alloy, the nucleation and growth of ?-Fe during the rapid quenching process can be minimized.

Abstract: An iron-based rare earth alloy magnet has a composition represented by the general formula: (Fe1-mTm)100-x-y-zQxRyMz, where T is at least one element selected from the group consisting of Co and Ni; Q is at least one element selected from the group consisting of B and C; R is at least one rare earth element substantially excluding La and Ce; and M is at least one metal element selected from the group consisting of Ti, Zr and Hf and always includes Ti. In this formula, the mole fractions x, y, z and m meet the inequalities of: 10 at %<x?20 at %; 6 at %?y<10 at %; 0.1 at %?z?12 at %; and 0?m?0.5, respectively.

Abstract: A nanocomposite magnet has a composition represented by (Fe1-mTm)100-x-y-z-nQxRyTizMn, where T is at least one of Co and Ni, Q is at least one of B and C, R is at least one rare earth element that always includes at least one of Nd and Pr and optionally includes Dy and/or Tb, and M is at least one element selected from the group consisting of Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb. The mole fractions x, y, z, m and n satisfy 10 at %<x?20 at %, 6 at %?y<10 at %, 0.5 at %?z?12 at %, 0?m?0.5 and 0 at %?n?10 at %, respectively. The nanocomposite magnet has an oxygen content of at most about 1,500 ppm by mass.

Abstract: A method of making a magnetic alloy material includes the steps of: preparing a melt of an alloy material having a predetermined composition; rapidly cooling and solidifying the melt to obtain a rapidly solidified alloy represented by: Fe100-a-b-cREaAbTMC where RE is at least one rare-earth element selected from La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er and Tm and including at least about 90 at % of La; A is at least one element selected from Al, Si, Ga, Ge and Sn; TM is at least one transition metal element selected from Sc, Ti, V, Cr, Mn, Co, Ni, Cu and Zn; and 5 at %?a?10 at 5%, 4.7 at% ?b?18 at % and 0 at %?c?9 at %; and producing a compound phase having an NaZn13-type crystal structure in at least about 70 vol % of the rapidly solidified alloy.

Abstract: A compound for a rare-earth bonded magnet includes a rare-earth alloy powder and a binder. The rare-earth alloy powder includes at least about 2 mass % of Ti-containing nanocomposite magnet powder particles with a composition represented by (Fe1-mTm)100-x-y-zQxRyMz, where T is Co and/or Ni; Q is B with or without C; R is at least one rare-earth element substantially excluding La and Ce; M is at least one metal element selected from Ti, Zr and Hf and always includes Ti; and 10<x?20 at %; 6?y<10 at %; 0.1?z?12 at %; and 0?m?0.5. The particles include at least two ferromagnetic crystalline phases, in which hard magnetic phases have an average crystal grain size of about 10 nm to about 200 nm, soft magnetic phases have an average crystal grain size of about 1 nm to about 100 nm; and the average crystal grain size of the soft magnetic phases is smaller than that of the hard magnetic phases.

Abstract: An iron-based rare earth alloy nanocomposite magnet has a composition represented by (Fe1-mTm)100-x-y-zQxRyTiz, where T is Co and/or Ni, Q is B and/or C and R is rare earth element(s) including substantially no La or Ce. x, y, z and m satisfy 10 at %<x?17 at %, 7 at %?y<10 at %, 0.5 at %?z?6 at % and 0?m?0.5, respectively. The magnet includes crystal grains of an R2T14Q type compound having an average grain size of 20 nm to 200 nm and a ferromagnetic iron-based boride that exists in a grain boundary between the crystal grains of the R2T14Q type compound. The boride is dispersed in, or present in the form of a film over, the grain boundary to cover at least partially the surface of the crystal grains of the R2T14Q type compound.

Abstract: A method of making a magnetic alloy material includes the steps of: preparing a melt of an alloy material having a predetermined composition; rapidly cooling and solidifying the melt to obtain a rapidly solidified alloy represented by: Fe100-a-b-cREaAbTMc where RE is at least one rare-earth element selected from La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er and Tm and including at least about 90 at % of La; A is at least one element selected from Al, Si, Ga, Ge and Sn; TM is at least one transition metal element selected from Sc, Ti, V, Cr, Mn, Co, Ni, Cu and Zn; and 5 at %?a?10 at %, 4.7 at %?b?18 at % and 0 at %?c?9 at %; and producing a compound phase having an NaZn13-type crystal structure in at least about 70 vol % of the rapidly solidified alloy.

Abstract: A melt of an alloy, represented (Fe1-mTm)100-x-y-zQxRyMz, where T is Co and/or Ni, Q is B and/or C, R is at least one rare-earth element, M is selected from Al, Si, Ti, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb; 10 at %?x?35 at %; 2 at %?y?10 at %; 0 at %?z?10 at %; and 0?m?0.5, is prepared. Next, the melt is brought into contact with, and rapidly cooled and solidified by, the surface of a rotating chill roller. The melt is teemed onto a guide member, of which the guide surface defines a tilt angle with a horizontal plane, runs down on the guide surface, and then is fed through at least one tubular hole onto a contact area on the surface of the chill roller.

Abstract: To make a raw alloy, consisting mostly of amorphous structure, highly productively and at a reduced cost for a nanocomposite magnet, a molten alloy represented by Fe100-x-y-zRxQyMz (where R is at least one element selected from Pr, Nd, Dy and Tb; Q is B and/or C; M is at least one element selected from Co, Al, Si, Ti, V, Cr, Mn, Ni, Cu, Ga, Zr, Nb, Mo, Ag, Pt, Au and Pb; and 1 at %?x<6 at %, 15 at %?y?30 at % and 0 at %?z?7 at %) is prepared. This molten alloy is rapidly cooled by a strip casting process in which the alloy is fed onto a chill roller, rotating at a peripheral velocity of 3 m/s to less than 20 m/s, at a feeding rate per unit contact width of 0.2 kg/min/cm to 5.2 kg/min/cm. In this manner, an alloy including at least 60 volume percent of amorphous phase can be obtained.

Abstract: To make a raw alloy, consisting mostly of amorphous structure, highly productively and at a reduced cost for a nanocomposite magnet, a molten alloy represented by Fe100-x-y-zRxQyMz (where R is at least one element selected from Pr, Nd, Dy and Tb; Q is B and/or C; M is at least one element selected from Co, Al, Si, Ti, V, Cr, Mn, Ni, Cu, Ga, Zr, Nb, Mo, Ag, Pt, Au and Pb; and 1 at %?x<6 at %, 15 at %?y?30 at % and 0 at %?z?7 at %) is prepared. This molten alloy is rapidly cooled by a strip casting process in which the alloy is fed onto a chill roller, rotating at a peripheral velocity of 3 m/s to less than 20 m/s, at a feeding rate per unit contact width of 0.2 kg/min/cm to 5.2 kg/min/cm. In this manner, an alloy including at least 60 volume percent of amorphous phase can be obtained.

Abstract: A method of making a material alloy for an iron-based rare earth magnet includes the step of forming a melt of an alloy with a composition of (Fe1-mTm)100-x-y-z-n(B1-pCp)xRyTi2Mn. T is Co and/or Ni; R is at least one element selected from Y (yttrium) and the rare earth elements; and M is at least one element selected from Al, Si, V, Cr, Mn, Ni, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb, wherein the following inequalities are satisfied: 10<x?25 at %, *6?y<10 at %, 0.5?z?12 at %, 0?m?0.5, 0?n?10 at % and 0?p?0.25. Next, the melt is fed onto a shoot with a guide surface tilted at about 1 degree to about 80 degrees with respect to a horizontal plane, thereby moving the melt onto a melt/roller contact region. The melt is then rapidly cooled using a chill roller to make a rapidly solidified alloy including an R2Fe14B phase.

Abstract: A nanocomposite magnet represented by the general formula: (Fe1-mTm)100-x-y-z-w-n(B1-pCp)xRyTizVwMn, where T is Co and/or Ni; R is a rare-earth element; M is at least one element selected from Al, Si, Cr, Mn, Cu, Zn, Ga, Nb, Zr, Mo, Ag, Ta and W; and x, y, z, w, n, m and p satisfy: 10 at %<x?15 at %; 4 at %?y<7 at %; 0.5 at %?z?8 at %; 0.01 at %?w?6 at %; 0 at %?n?10 at %; 0?m?0.5; and 0.01?p?0.5, respectively. The magnet includes a hard magnetic phase with an R2Fe14B type crystal structure and a soft magnetic phase. At least one of the coercivity and the maximum energy product of the nanocomposite magnet is at least 1% higher than that of a magnet including no V.