Abstract: A method of producing a permanent magnet includes: melting boron, cobalt, a metallic alloy component, a mixed rare earth material, and iron together to form a melted alloy and forming a first alloy ingot using the melted alloy, wherein the permanent magnet comprises about 28-35 weight percent of rare earth material; crushing the first alloy ingot into particles having a first average particle diameter less than about 3 millimeters; milling the particles to form a powder mixture with a second average particle diameter in the range from about 2.

Abstract: A permanent magnet comprises boron, cobalt, a metallic alloy component, about 28-35 weight percent of mixed rare-earth material, and iron as a balance. The metallic alloy component is selected from the group consisting of aluminum, copper, niobium, gallium, vanadium, chromium, zirconium, and combinations thereof. The mixed rare-earth material comprises light rare-earth material and heavy rare-earth material. The light rare-earth material comprises at least about 50 weight percent of praseodymium and about 5-50 weight percent of neodymium. The heavy rare-earth material comprises dysprosium or a combination of dysprosium and terbium. The mixed rare-earth material comprises about 3-45 weight percent of heavy rare-earth material. A sum of intrinsic coercivity in the unit of kilo Oersted (kOe) and maximum energy product in unit of mega gauss Oersteds (MGOe) of the permanent magnet is at least about 55.

Abstract: In accordance with certain embodiments, the present invention provides a magnetizing system. This system includes a guide channel that is configured to receive a ferromagnetic element. When in this channel, a magnetic field source of the system is operable to magnetize the ferromagnetic element. Also, the exemplary system includes an actuation mechanism that drives the ferromagnetic element through the guide channel. Because a positioning mechanism of the system has aligned the guide channel with a slot of an electromagnetic machine component, the ferromagnetic element is routed through the channel and into the slot.

Abstract: A system and method for a permanent magnet, having boron, iron, and a rare-earth material. The rare-earth material includes neodymium, at least 50 weight percent praseodymium, 0-20 weight percent terbium, and 5-25 weight percent dysprosium, wherein the permanent magnet comprises an intrinsic coercivity of at least 17 kilo Oersteds. Due to this high intrinsic coercivity, the permanent magnet may be subjected to high-temperature (e.g., greater than 80° C.) applications (e.g., as a component of a motor, generator, and so forth). In one exemplary application, a generator within a commercial wind turbine or windmill incorporates 3 tons of the permanent-magnet material.