Abstract: As-cast permanent magnets are provided that preferably have a main 1:7 Ce-based main matrix phase to achieve improved as-cast extrinsic magnetic properties using certain optimum casting conditions without the need for subsequent heat treatment. As-cast magnets also can be subjected to heat treatment to achieve similar improved extrinsic magnetic properties.

Abstract: As-cast permanent magnets are provided that preferably have a main 1:7 Ce-based main matrix phase to achieve improved as-cast extrinsic magnetic properties using certain optimum casting conditions without the need for subsequent heat treatment. As-cast magnets also can be subjected to heat treatment to achieve similar improved extrinsic magnetic properties.

Abstract: Embodiments of the present invention provide an electromagnet alignment system for AM or 3D printing technology providing improved in-situ alignment of the magnetic particulate material as it is dispensed during deposition to form a 3D shape. In-situ alignment of the magnetic particulate material can be controlled to be unidirectional or multi-directional.

Abstract: A method of increasing anisotropy of magnetic materials formed by a hydrogenation-disproportionation-desorption-recombination (HDDR) process is provided. The method includes subjecting a starting magnetic material to a hydrogenation-disproportionation (HD) step in the presence of a magnetic field to obtain intermediate materials. The strength of the applied magnetic field is between 0.25 T and 9 T, optionally less than or equal to 2 T. The HD step may be performed for a period of time between 10 and 60 minutes at a temperature of at least 600° C., optionally in the range of 600° C. to 900° C. Subsequently, the intermediate materials are subjected to a desorption-recombination (DR) step to obtain a magnetic powder. Application of the magnetic field during the hydrogenation-disproportionation step increases the magnetic anisotropy of the obtained magnetic powder. Magnetic powders obtained by the method and bonded magnets formed with the magnetic powders are also provided.

Abstract: Embodiments of the present invention provide an electromagnet alignment system for AM or 3D printing technology providing improved in-situ alignment of the magnetic particulate material as it is dispensed during deposition to form a 3D shape. In-situ alignment of the magnetic particulate material can be controlled to be unidirectional or multi-directional.

Abstract: Improved manufacturing processes and resulting anisotropic permanent magnets, such as for example alnico permanent magnets, having highly controlled and aligned microstructure in the solid state are provided. A certain process embodiment involves applying a particular orientation and strength of magnetic field to loose, binder-coated magnet alloy powder particles in a compact-forming device as they are being formed into a compact in order to preferentially align the magnet alloy powder particles in the compact. The preferential alignment of the magnet alloy powder particle is locked in place in the compact by the binder after compact forming is complete. After removal from the device, the compact can be subjected to a subsequent sintering or other heat treating operation.

Abstract: Improved manufacturing processes and resulting anisotropic permanent magnets, such as for example alnico permanent magnets, having highly controlled and aligned microstructure in the solid state are provided. A certain process embodiment involves applying a particular orientation and strength of magnetic field to loose, binder-coated magnet alloy powder particles in a compact-forming device as they are being formed into a compact in order to preferentially align the magnet alloy powder particles in the compact. The preferential alignment of the magnet alloy powder particle is locked in place in the compact by the binder after compact forming is complete. After removal from the device, the compact can be subjected to a subsequent sintering or other heat treating operation.

Abstract: Magnet microstructure manipulation in the solid state by controlled application of a sufficient stress in a direction during high temperature annealing in a single-phase region of heat-treatable magnet alloys, e.g., alnico-type magnets is followed by magnetic annealing and draw annealing to improve coercivity and saturation magnetization properties. The solid-state process can be termed highly controlled abnormal grain growth (hereafter AGG) and will make aligned sintered anisotropic magnets that meet or exceed the magnetic properties of cast versions of the same alloy types.

Abstract: Embodiments of the present invention provide an electromagnet alignment system for AM or 3D printing technology providing improved in-situ alignment of the magnetic particulate material as it is dispensed during deposition to form a 3D shape. In-situ alignment of the magnetic particulate material can be controlled to be unidirectional or multi-directional.

Abstract: Magnet microstructure manipulation in the solid state by controlled application of a sufficient stress in a direction during high temperature annealing in a single-phase region of heat-treatable magnet alloys, e.g., alnico-type magnets is followed by magnetic annealing and draw annealing to improve coercivity and saturation magnetization properties. The solid-state process can be termed highly controlled abnormal grain growth (hereafter AGG) and will make aligned sintered anisotropic magnets that meet or exceed the magnetic properties of cast versions of the same alloy types.

Abstract: Magnet microstructure manipulation in the solid state by controlled application of a sufficient stress in a direction during high temperature annealing in a single-phase region of heat-treatable magnet alloys, e.g., alnico-type magnets is followed by magnetic annealing and draw annealing to improve coercivity and saturation magnetization properties. The solid-state process can be termed highly controlled abnormal grain growth (hereafter AGG) and will make aligned sintered anisotropic magnets that meet or exceed the magnetic properties of cast versions of the same alloy types.

Abstract: Improved manufacturing processes and resulting anisotropic permanent magnets, such as for example alnico permanent magnets, having highly controlled and aligned microstructure in the solid state are provided. A certain process embodiment involves applying a particular orientation and strength of magnetic field to loose, binder-coated magnet alloy powder particles in a compact-forming device as they are being formed into a compact in order to preferentially align the magnet alloy powder particles in the compact. The preferential alignment of the magnet alloy powder particle is locked in place in the compact by the binder after compact forming is complete. After removal from the device, the compact can be subjected to a subsequent sintering or other heat treating operation.

Abstract: Magnet microstructure manipulation in the solid state by controlled application of a sufficient stress in a direction during high temperature annealing in a single-phase region of heat-treatable magnet alloys, e.g., alnico-type magnets is followed by magnetic annealing and draw annealing to improve coercivity and saturation magnetization properties. The solid-state process can be termed highly controlled abnormal grain growth (hereafter AGG) and will make aligned sintered anisotropic magnets that meet or exceed the magnetic properties of cast versions of the same alloy types.

Abstract: A permanent magnet operable above about 125 C to about 200 C has a major phase represented by MRE2(Fe, Co)14B wherein said MRE comprises two or more rare earth elements selected from the group consisting of La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, and Y wherein one of the rare earth elements is chosen from one or more of La, Ce, Pr, Nd, Eu, and Gd but in an amount not exceeding 45 atomic % of the magnet and wherein at least 50% atomic % of MRE comprises Y and at least one of Dy, Ho, and Tb. The total content of the at least one of Dy, Ho, and Tb is in the range of 0 to 4 weight % of the total mass of the magnet.