Abstract: A method of boriding a metal comprises forming a molten electrolyte comprising between about five weight percent and about fifty weight percent boron oxide, and contacting at least a portion of a metal with the molten electrolyte. Electrical current is applied to at least a portion of the metal while maintaining a temperature of the molten electrolyte below about 700° C. to diffuse boron atoms from the molten electrolyte into a surface of the at least a portion of the metal. A downhole tool including at least one borided component is also disclosed.

Abstract: In one aspect, the present invention is directed to methods for extracting rare earth metals from ores comprising reduction of rare earth metal oxyfluorides. In another aspect, the invention relates to an apparatus for extracting rare earth metals from ores comprising reduction of rare earth metal oxyfluorides. The methods and apparatuses described herein generate rare earth metals from ores with reduced requisite pre-removal of metal oxides found as natural impurities in ores.

Abstract: The present invention pertains to a method for removing a substance (X) from a solid metal or semi-metal compound (M1X) by electrolysis in a melt of M2Y, which comprises conducting the electrolysis under conditions such that reaction of X rather than M2 deposition occurs at a electrode surface, and that X dissolves in the electrolyte M2Y. The substance X is either removed from the surface (i.e., M1X) or by means of diffusion extracted from the case material. The temperature of the fused salt is chosen below the melting temperature of the metal M1. The potential is chosen below the decomposition potential of the electrolyte.

Abstract: A process for electroplating and annealing thin-films of nickel-iron alloys having from 63% to 81% iron content by weight to produce pole pieces having saturation flux density (BS) in the range from 1.9 to 2.3 T (19 to 23 kG) with acceptable magnetic anisotropy and magnetostriction and a coercivity (HC) no higher than 160 A/m (2 Oe). The desired alloy layer properties, including small crystal size and minimal impurity inclusions, can be produced by including higher relative levels of Fe++ ions in the electroplating bath while holding the bath at a lower temperature while plating from a suitable seed layer. The resulting alloy layer adopts a small crystal size (BCC) without significant inclusion of impurities, which advantageously permits annealing to an acceptable HC while retaining the high BS desired.

Abstract: A method for the production of a master alloy including the steps of; introducing mixed ores comprising the metals of the alloy; introducing the mixed ores into an electrochemical cell, the cell containing a liquid electrolyte comprising a fused salt or mixture of salts generally designated as M2Y in which contaminants X contained in the mixed ores are soluble, and a relatively inert anode; conducting electrolysis under conditions favourable to the selective dissolution of contaminants contained in the mixed ores in preference to the deposition of the M2 cation; and following electrolysis, reclaiming the purified mixed ore form the cathode.

Abstract: The present invention provides amorphous non-laminar nickel phosphorous alloys, amorphous non-laminar nickel cobalt phosphorous alloys, or amorphous non-laminar cobalt phosphorous alloys. These alloys are useful in the formation of metal articles and metal-coated articles, including high precision devices and molds for plastics. In addition, the alloys of the present invention are useful in repairing damaged metal surfaces.

Abstract: Provided are a method of forming a magnetic layer pattern and a method of manufacturing a thin film magnetic head, which can reduce the number of manufacturing steps and thus reduce the manufacturing time. A precursory nonmagnetic layer and a precursory bottom pole layer are formed in this sequence so as to cover a frame pattern formed on an underlayer (a top shield layer) and having an opening. Then, the precursory nonmagnetic layer and the precursory bottom pole layer are patterned by polishing the overall surface by CMP until at least the frame pattern is exposed, and thus a nonmagnetic layer and a bottom pole are selectively formed. The number of manufacturing steps can be reduced and thus the manufacturing time can be reduced, as compared to the case of forming the nonmagnetic layer and the bottom pole without forming the frame pattern.

Abstract: A method for recovering reusable elements including rare earth elements from a rare earth-nickel alloy is disclosed, including the steps of:preparing a slurry of the rare earth-nickel alloy,adding a diluted nitric acid solution to the slurry over a period of time under stirring at a temperature not higher than 50.degree. C. while maintaining pH of a resulting mixture at 5 or higher to dissolve soluble metals including rare earth metals, andseparating an undissolved residue containing nickel from a rare earth-containing nitrate solution by filtration.

Abstract: A method of producing neodymium in an electrolytic cell without formation of perfluorinated carbon gases (PFCs), the method comprising the steps of providing an electrolyte in the electrolytic cell and providing an anode in an anode region of the electrolyte and providing a cathode in a cathode region of the electrolytic cell. Dissolving an oxygen-containing neodymium compound in the electrolyte in the anode region and maintaining a more intense electrolyte circulation in the anode region than in the cathode region. Passing an electrolytic current between said anode and said cathode and depositing neodymium metal at the cathode, preventing the formation of perfluorinated carbon gases by limiting anode over voltage.