Abstract: The invention provides rare earth-free permanent magnetic materials and methods of making them. The materials can be used to produce magnetic structures for use in a wide variety of commercial applications, such as motors, generators, and other electromechanical and electronic devices. Magnets fabricated using the materials can be substituted for magnets requiring rare earth elements that are costly and in limited supply. The invention provides two different types of magnetic materials. The first type is based on an iron-nickel alloy that is doped with one or more doping elements to promote the formation of L10 crystal structure. The second type is a nanocomposite particle containing magnetically hard and soft phases that interact to form an exchange spring magnetic material. The hard phase contains Fe or FeCo, and the soft phase contains AlMnC.

Abstract: An aspect of the present disclosure relates to an alloy composition, which may include 52 atomic percent to 68 atomic percent iron, 13 to 21 atomic percent nickel, 2 to 12 atomic percent cobalt, 10 to 19 atomic percent boron, optionally 1 to 5 atomic percent carbon, and optionally 0.3 to 16 atomic percent silicon. The alloy may include 5 to 95% by volume of one or more spinodal microconstituents, wherein the microconstituents exhibit a length scale less than 50 nm in a glass matrix.

Abstract: The invention provides rare earth-free permanent magnetic materials and methods of making them. The materials can be used to produce magnetic structures for use in a wide variety of commercial applications, such as motors, generators, and other electromechanical and electronic devices. Magnets fabricated using the materials can be substituted for magnets requiring rare earth elements that are costly and in limited supply. The invention provides two different types of magnetic materials. The first type is based on an iron-nickel alloy that is doped with one or more doping elements to promote the formation of L10 crystal structure. The second type is a nanocomposite particle containing magnetically hard and soft phases that interact to form an exchange spring magnetic material. The hard phase contains Fe or FeCo, and the soft phase contains AlMnC.

Abstract: An aspect of the present disclosure relates to an alloy composition, which may include 52 atomic percent to 68 atomic percent iron, 13 to 21 atomic percent nickel, 2 to 12 atomic percent cobalt, 10 to 19 atomic percent boron, optionally 1 to 5 atomic percent carbon, and optionally 0.3 to 16 atomic percent silicon. The alloy may include 5 to 95% by volume of one or more spinodal microconstituents, wherein the microconstituents exhibit a length scale less than 50 nm in a glass matrix.

Abstract: A method of making quasicrystalline alloy particulates wherein an alloy is superheated and the melt is atomized to form generally spherical alloy particulates free of mechanical fracture and exhibiting a predominantly quasicrystalline in the atomized condition structure. The particulates can be plasma sprayed to form a coating or consolidated to form an article of manufacture.

Abstract: A method is disclosed for detecting the T.sub.1 phase in aluminum-lithium alloys through simultaneous measurement of conductivity and hardness. In employing eddy current to measure conductivity, when the eddy current decreases with aging of the alloy, while the hardness of the material continues to increase, the presence of the T.sub.1 phase may be detected.