Abstract: A method for the high volume manufacture of Fe-B-R-T alloy powders without sacrificing the resultant magnetic properties (such as intrinsic magnetic coercivity) of the alloy involves hydrogen decrepitation of vacuum cast or die-upset billets of the alloy. Hydriding is carried out at a partial pressure of hydrogen of between 250 and 760 mm Hg at 100.degree. to 500.degree. C. for 30 minutes to 6 hours or longer, depending upon load size. Dehydriding occurs in a vacuum below 10.sup.-2 mm Hg or in an inert atmosphere possessing a partial pressure of hydrogen below 10.sup.-2 mm Hg. The alloy powder is preferably incorporated in matrix or composite magnets by the addition of a binder prior to pressing and orienting. The binder may set during pressing in a hot die, or by heating after pressing in a cold die.

Abstract: An organic binder or lubricant in a pressed or compacted green body formed of cobalt-rare earth intermetallic particles is substantially removed from the green body before the carbon can react with the rare earth during sintering. This is accomplished by exposing the green body to a temperature of about 100.degree. to 300.degree.C in a hydrogen-containing atmosphere. The hydrogen reacts with the organic binder or lubricant which allows the resulting organic molecules to volatilize from the green body. The green body is then sintered after which it is cooled to room temperature.

Abstract: The invention covers the use of reactive hydrogen-containing atmospheres in the sintering and heat-aging of cobalt-rare earth intermetallic products.

Abstract: Magnets are produced by dissolving in a solvent organic polymer which is a binder for magnetic powder, adding a magnetic powder to the solution, then adding to the solution a vehicle in which the polymer is insoluble. The vehicle is added until the polymer has precipitated onto the magnetic particles. These coated particles are then dried and hot pressed within an orienting magnetic field to produce the magnet.