Abstract: An iron-based rare-earth alloy powder includes: a first iron-based rare-earth alloy powder, which has a mean particle size of 10 &mgr;m to 70 &mgr;m and of which the powder particles have aspect ratios of 0.4 to 1.0; and a second iron-based rare-earth alloy powder, which has a mean particle size of 70 &mgr;m to 300 &mgr;m and of which the powder particles have aspect ratios of less than 0.3. The first and second iron-based rare-earth alloy powders are mixed at a volume ratio of 1:49 to 4:1. In this manner, an iron-based rare-earth alloy powder with increased flowability and a compound to make a magnet are provided.

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 &agr;-Fe during the rapid quenching process can be minimized.

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)xRyTizMn. 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: 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 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: 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: An iron-based rare-earth alloy powder includes: a first iron-based rare-earth alloy powder, which has a mean particle size of 10 &mgr;m to 70 &mgr;m and of which the powder particles have aspect ratios of 0.4 to 1.0; and a second iron-based rare-earth alloy powder, which has a mean particle size of 70 &mgr;m to 300 &mgr;m and of which the powder particles have aspect ratios of less than 0.3. The first and second iron-based rare-earth alloy powders are mixed at a volume ratio of 1:49 to 4:1. In this manner, an iron-based rare-earth alloy powder with increased flowability and a compound to make a magnet are provided.

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: 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: 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 melt of an iron-based rare earth material alloy, represented by (Fe1-mTm)100-x-y-zQxRyMz, is prepared, wherein T is Co and/or Ni; Q is B and/or C; R is selected from Y (yttrium) and the rare earth elements; 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≦x≦30 at %; 2%≦y<10 at %; 0≦z≦10 at % and 0≦m≦0.5. The melt is fed onto a guide to form a flow of the melt thereon and move the melt onto a melt/chill roller contact region, where the melt is rapidly cooled by the chill roller to make a rapidly solidified alloy. An oxygen concentration of the melt yet to be fed onto the guide is controlled at about 3,000 ppm or less in mass percentage.

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 the surface of the crystal grains of the R2T14Q type compound at least partially.

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 melt of an iron-based rare earth material alloy, represented by (Fe1-mTm)100-x-y-zQxRyMz, is prepared. T is Co and/or Ni; Q is B and/or C; R is selected from Y (yttrium) and the rare earth elements; 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≦x≦30 at %; 2%≦y<10 at %; 0≦z≦10 at % and 0≦m≦0.5. The melt is fed onto a guide to form a flow of the melt thereon and move the melt onto a melt/chill roller contact region, where the melt is rapidly cooled by the chill roller to make a rapidly solidified alloy. An oxygen concentration of the melt yet to be fed onto the guide is controlled at about 3,000 ppm or less in mass percentage.

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(1−pCp)xRyTizMn. 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: The method for producing iron-base alloy permanent magnet powder of the present invention includes the steps of: chilling an Fe—R—B molten alloy by melt quenching, thereby forming a rapidly solidified alloy having a thickness in a range of 80 &mgr;m to 300 &mgr;m; crystallizing the rapidly solidified alloy by heat treatment, thereby producing an alloy having permanent magnet properties; and pulverizing the alloy to produce powder having an average particle size in a range of 50 &mgr;m to 300 &mgr;m or less and a ratio of minor axis size to major axis size of powder particles in a range of 0.3 to 1.0.

Abstract: The inventive method for preparing nanocomposite magnet powder includes the step of preparing material alloy powder for a nanocomposite magnet represented by a general formula Fe100−x−y−z−uRxByCozMu where R is a rare-earth element of which 90-100 atomic percent is Pr and/or Nd while 0-10 atomic percent is another lanthanoid and/or Y, and the molar fractions x, y, z and u meet the inequalities of 2≦x≦6, 16≦y≦20, 0.2≦z≦7 and 0.01≦u≦7, respectively. The powder includes a metastable phase and an amorphous structure existing in a metal structure. Heat treatment is performed for the material alloy powder to crystallize Fe3B and Fe—R—B compounds from the amorphous structure. An integral value of the difference between a temperature-time curve represented by the temperature of the material alloy powder as a function of the heat treatment time during the heat treatment and a reference temperature-time curve is in a range from 10° C.

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)xRyTizMn. 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: The present invention is presented with the object of providing a manufacturing method for thin-plate magnets that, as cast, exhibit an intrinsic coercive force iHc of 2.5 kOe or greater and a residual magnetic flux density Br of 9 kG or greater, exhibit a performance-to-cost ratio comparable to hard ferrite magnets, and exhibit a fine crystalline structure with a thickness of 70 to 500 &mgr;m wherewith magnetic circuits can be made smaller and thinner. By employing alloy melts to which specific elements have been added, in a process wherein alloy melts of specific composition are continuously cast on a rotating cooling roller or rollers in a reduced-pressure inert or inactive gas atmosphere at 30 kPa or less, and fine crystalline permanent magnets having a fine crystalline structure of 10 to 50 nm are fabricated, fine crystalline permanent magnets having a thickness of 70 to 500 &mgr;m can be obtained wherein iHc is improved to 2.

Abstract: With the invention of establishing fabrication methods for cheaply produced (Fe,Co)—Cr—B—R-type bonded magnets or (Fe,Co)—Cr—B—R—M-type bonded magnets containing few rare earth elements having a coercive force iHc above 5 kOe and a residual magnetic flux density Br above 5.