Abstract: A method for fabricating a titanium aluminide composite structure consisting of a filamentary material selected from the group consisting of silicon carbide, silicon carbide-coated boron, boron carbide-coated boron, titanium boride-coated silicon carbide and silicon-coated silicon carbide, embedded in an alpha-2 titanium aluminide metal matrix, which comprises the steps of providing a first beta-stabilized Ti.sub.3 Al powder containing a desired quantity of beta stabilizer, providing a second beta-stabilized Ti.sub.3 Al powder containing a sacrificial quantity of beta stabilizer in excess of the desired quantity of beta stabilizer, coating the filamentary material with the second powder, fabricating a preform consisting of the thus-coated filamentary materials surrounded by the first powder, and applying heat and pressure to consolidate the preform.The composite structure fabricated using the method of this invention is characterized by its lack of a denuded zone and absence of fabrication cracking.

Abstract: In a process for making tools from medium and high alloy steels or stellites by superplastic precision forming a powder metallurgically produced starting material with an equiaxed structure and more than 30% by volume of carbidic and/or boridic precipitated phase of particle size 1 to 0.2 .mu.m is given a matrix grain size of 1 to 3 .mu.m by thermomechanical processing (hot forming) and formed in the superplastic state.

Abstract: The invention relates to a method of making permanent magnets, especially rare-earth ion permanent magnets composed of compacted Fe-B-R type alloy particles. Accordingly, the method provides compacting the magnetic particles into a desired shape having voids between some of the compacted particles. The voids between the particles are filled with a sealing agent and the compact is further coated with either an organic coating or metallic coating.

Abstract: A complex boride cermet having high strength and high toughness, which comprises a hard phase composed mainly of a boride of (Mo.sub.1-x W.sub.x).sub.2 NiB.sub.2 formed by substituting a part of Mo of Mo.sub.2 NiB.sub.2 by W, and a matrix alloy phase composed mainly of Ni and containing Mo, and a complex boride cermet comprising a hard phase composed mainly of Mo.sub.2 NiB.sub.2 or (Mo.sub.1-x W.sub.x).sub.2 NiB.sub.2 and a matrix of an alloy phase composed mainly of Ni and containing Mo, which is characterized in that carbon or/and nitrogen, and optionally at least one metal selected from the metals of Groups 4B and 5B and Cr, are incorporated to further improve the strength and toughness. Such complex boride cermet has high strength and high toughness and maintains such properties even at elevated temperatures of from 600.degree. to 900.degree. C.

Abstract: Self-supporting bodies are produced by reactive infiltration of a parent metal into a boron carbide material which may contain one or both of a boron donor material and a carbon donor material. The reactive infiltration typically results in a composite comprising a boron-containing compound, a carbon-containing compound and residual metal, if desired. The mass to be infiltrated may contain one or more inert fillers admixed with the boron carbide material, boron-containing compound and/or carbon-containing compound. The relative amounts of reactants and process conditions may be altered or controlled to yield a body containing varying volume percents of ceramic, metal, ratios of one ceramic to another and porosity.

Abstract: Permanent magnets are prepared by a method comprising mixing a particulate rare earth-iron-boron alloy with a particulate transition metal, aligning the magnetic domains of the mixture, compacting the aligned mixture to form a shape, and sintering the compacted shape.

Abstract: Rare-earth alloy anisotropic powders consist of, in atomic percent, over 12 percent and not more than 20 percent of R (R is at least one on neodymium and praseodymium or at least one of them and or more rare-earth elements), not less than 4 percent and not more than 10 percent of boron, not less than 0.05 percent and not more than 5 percent of copper and the rest that consists of iron and unavoidable impurities. Up to 20 percent of the iron contained is replaceable with cobalt. The alloy powders are made up of flat crystal grains having mean thickness h (the shortest measure), d not smaller than 0.01 .mu.m and not larger than 0.5 .mu.m and ratio d/h not smaller than 2, where d is the means measure of the grains taken at right angles to the widthwide direction thereof, and the alloy powders are magnetically anisotropic.

Abstract: A nickel-based superalloy article formed from particles of the superalloy is processed to have a microstructure which is resistant to failure when processed using high strain thermomechanical processes. Articles having the desired microstrucuture are produced by hot isostatically pressing powder of the superalloy in a specified temperature range bounded by the incipient melting temperature as a minimum and the solvus temperature of stable high temperature phases. The compact is held under pressure in the specified temperature range to diffuse deleterious phases which exist as a result of the initial powder atomization operation. The powder compact thus formed can be processed using conventional processes to produce material for subsequent thermomechanical processing using high strain rate forging equipment and retain the benefits of chemical uniformity and cleanliness associated with traditional powder metal processes.

Abstract: Permanent magnets are prepared by a method comprising mixing a particulate rare earth-iron-boron alloy with a particulate additive metal powder, compacting the aligned mixture to form a shape, and heating the compacted shape at a temperature at least 150.degree. C. less than the sintering temperature of a rare earth-iron-boron alloy and usually in the range from about 700.degree. C. to less than 850.degree. C.

Abstract: A dispersion strengthened copper alloy containing a copper matrix, and dispersion particles dispersed in the copper matrix within a range of 0.5 to 6 vol %. In this alloy, an average diameter of a matrix region where the dispersion particles are not present is 0.3 .mu.m or less, and the total amount of solid solution elements contained in the copper matrix is determined such that, when this amount of the solid solution elements is added to pure copper, the electric conductivity of the matrix is lowered by 5% IACS or less.

Abstract: The subject of this invention is the development of new alloys along with new processing approaches for the utilization of the alloys. A particular class of alloys comprises at least one noble metal selected from the group comprising gold, palladium, silver and copper and an amount of between about 0.20 weight percent and about 0.80 weight percent of at least one metalloid selected from the group of metalloids consisting of boron, phosphorous, silicon and lithium. Rapid solidification technology in powder fabrication and the addition of metalloids have been combined to produce a new class of palladium based alloys. The metalloid additions greatly increase the hardness, enhance the fine grain structure and aid sintering densification. Net-shape forming is a benefit derived from the characteristics of the new alloys.

Abstract: A process of making anisotropic permanent magnets by extruding a rare earth magnetic alloy below the melting temperature of the alloy at an extrusion ratio of from 10:1 to 26:1.

Abstract: This invention relates generally to materials and processes for making materials and, more particularly, to high performance boride dispersion strengthened materials, including alloy-modified, boride dispersion strengthened materials and techniques for making such materials.

Abstract: Magnesium alloy having a breaking load of at least 290 MPa, more particularly at least 330 MPa, having the following composition by weight: Al 2-11%, Zn 0-12%, Mn 0-0.6%, Ca 0-7%, but with the presence of at least Zn and/or Ca, having a mean particle size less than 3 .mu.m, a homogeneous matrix reinforced with intermetallic compounds having a size less than 1 .mu.m precipitated at the grain boundaries, this structure remaining unchanged after storage at 200.degree. C. for 24 hours; and a process for producing it by rapid solidification and consolidation by extrusion at a temperature between 200.degree. and 350.degree. C.

Abstract: When V is added to an Nd--Fe--B sintered magnet so as to modify the minority phase such that B in excess of a stoichiometric composition of R.sub.2 Fe.sub.14 B compound-phase, essentially does not form RFe.sub.4 B.sub.4 -compound minority phases but forms a finely dispersed V--T--B compound minority phase (T is Fe, and in a case containing Co, T is Fe and Co), the coercive force (iHc) is enhanced to 15 kOe or more but becomes very sensitive to heat treatment temperature. This drawback is eliminated by the addition of from 0.01 to 1 at % of Cu.

Abstract: The invention describes a method of manufacturing a magnet on the basis of Re.sub.2 Fe.sub.14 B. To this end, a shaped body of the said composition is sintered by means of induction heating to a density exceeding 95% of the theoretical maximum density. The method according to the invention enables the manufacture of magnets having excellent properties in a very short time, these properties being: a high energy product, a large remanence, a high density, a large intrinsic coercive force and a small particle size.

Abstract: An improved method is proposed for the preparation of a sintered permanent magnet of a rare earth-iron-boron alloy having remarkably improved magnetic properties and stability by the powder metallurgical process. The scope of the inventive method consists in the particle size classification of the alloy powder for compression molding into a powder compact to be sintered, by which particles having a finer particle diameter and, preferably, a coarser particle diameter than the respective critical values are removed so as to effectively prevent oxidation of the too fine particles and improving the magnetic orientation of the particles as well as the sintering behavior of the particles.

Abstract: A process is provided for igniting a mixed powder material compact containing sufficient fuel to support an exothermic reaction between ingredients contained in the compact. The ignition is achieved in an inert atmosphere with an electric arc produced by an electrode without contacting the compact and thereby initiating the reaction.

Abstract: The invention relates to a method of producing a sintered Nd-Fe-B magnet which has a cylindrical or annular shape and is magnetized in radial directions with polar anisotropic orientation. In a cylindrical mold cavity filled with a Nd-Fe-B magnetic alloy powder a pulse of magnetic field is produced so as to cause polar anisotropic orientation of the magnetic powder with at least six poles distributed around the circumference, and a pulse-like pressure is applied to the powder in the mold cavity to compact the powder into a cylindrically shaped body while the pulse of magnetic field is lasting. The shaped body is sintered, and subsequently the side surface of the sintered body is abraded to remove projecting regions, which are attributed to anisotropic shrinkage during sintering, until the surface becomes accurately cylindrical.

Abstract: The proposed invention is used for the manufacture from the obtained composite of cutting tools, hard alloy tooling, dies and other products. A method according to the invention involves preparing a mixture, compacting it, placing the mixture into a synthesis zone, igniting the mixture, with subsequent reaction of components of the mixture under combustion conditions. Then cure is carried out during a period ranging from about 0.1 seconds to about 0.5 hours, and the hot combustion products are compacted under pressure at an average pressure rise rate ranging from about 10 to about 2000 kgf/cm.sup.2.s, with subsequent cure of the compacted product under isobaric conditions to complete homogenization of the composite, with subsequent cooling thereof to obtain an end composite.

Abstract: Impact resistant clad composite armor and method for forming such armor. The impact resistant clad composite armor includes a ceramic core, and a layer of metal surrounding the ceramic material and bonded to the ceramic core. The metal layer is formed by cold isostatically pressing powder metal surrounding the ceramic core to a high initial density followed by vacuum sintering. The composite armor may be hot isostatically pressed to densify the powder metal to approximately 99% full density.

Abstract: A process making anisotropic permanent magnets by extruding a neodymium-iron-boron alloy having a grain size of from 500.ANG. to 2000.ANG.at a temperature less than the melting temperature of the alloy at an extrusion ratio of from 10:1 to 26:1.

Abstract: A method of producing a magnetically anisotropic Nd-Fe-B magnet material comprising the steps of: charging a green body produced by pressing a flaky or powdery material consisting of an amorphous alloy and/or a finely crystallized alloy, into a cavity defined by a die having a hole extending therethrough, a lower plunger inserted into said hole, and an upper plunger having a larger diameter than that of said hole; pressing said green body by elevating said lower plunger while keeping a temperature thereof (pressing temperature) at 600.degree.-850.degree.; elevating the resulting pressed body by elevating said lower plunger while heating; and upsetting said pressed body while keeping a temperature thereof (upsetting temperature) at 600.degree.-850.degree. C. to provide it with magnetic anisotropy.

Abstract: A magnetically anisotropic hot-worked magnet made of an R-T-B alloy containing a transition metal T as a main component, a rare earth element R including yttrium, and boron B; the magnet having fine crystal grains having an average grain size of 0.02-1.0 .mu.m, and having a carbon content of 0.8 weight % or less than an oxygen content of 0.5 weight % or less. The angular variance of orientation of the crystal grains is within 30.degree. from the C axes of the crystal grains when measured by X-ray. This magnet can be produced by mixing the magnet flakes with an additive composed of at least one organic compound having a boiling point of 50.degree. C. or higher.

Abstract: The invention relates to sintered hard metals having high cutting properties, particularly plastic deformation resistance at high temperatures, crater resistance and the like, suitable for use as cutting tools, wear resistant tools and materials for dies, and the method for producing the same. The invention has for an object to obtain both sintered hard metals having the aforesaid high properties by sintering metallic components comprising IVa group metals, VIa group metals or metals of both groups substituted by Va group metals up to 60 mol % respectively, a B-1 type solid solution hard phase consisting of non-metallic components of C, N and O, and a metallic bonding phase, in a CO gas atmosphere, and to sintered hard metals in which an uniform hardness is imparted to the surface and interior thereof by the method of sintering the said sintered hard metal in a CO gas atmosphere.

Abstract: The present invention relates to a method of preparing an alloy for use as a cutting tool material comprising hard principles and binder phase by which a uniform distribution of the hard principles in the binder phase is obtained, and the resulting product.

Abstract: A titanium-based metal matrix microcomposite material. About 1% to about 25% by weight TiB.sub.2 is substantially uniformly incorporated in a titanium-based alloy matrix. The microcomposite material is formed by sintering at a temperature selected to preclude diffusion of TiB.sub.2 into the matrix. The microcomposite material may be used in a process for cladding a macrocomposite structure.

Abstract: A high energy rare earth-ferromagnetic metal permanent magnet is disclosed which is characterized by improved intrinsic coercivity and is made by forming a particulate mixture of a permanent magnet alloy comprising one or more rare earth elements and one or more ferromagnetic metals and forming a second particulate mixture of a sintering alloy consisting essentially of 92-98 wt. % of one or more rare earth elements selected from the class consisting of Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, and mixtures of two or more of such rare earth elements, and 2-8 wt. % of one or more alloying metals selected from the class consisting of Al, Nb, Zr, V, Ta, Mo, and mixtures of two or more of such metals. The permanent magnet alloy particles and sintering aid alloy are mixed together and magnetically oriented by immersing the mixture in an axially aligned magnetic field while cold pressing the mixture.

Abstract: A sintered ferro alloy comprises 5 to 25 wt % of one or two elements selected from Mo and W, 2 to 10 wt % of Cr, 0.1 to 0.9 wt % of Si, less than or equal to 0.7 wt % of Mn, less than or equal to 0.05 wt % of P, 0.5 to 2.0 wt % of C, 0.5 to 2.0 wt % of B, 0.1 to 7.0 wt % of at least one element selected from borides of La, Ce, Nd, Sm, Eu, Gd, Yb, Y or Sc, residual Fe, and contaminants. Also the alloy may comprise less than or equal to 20 wt % of at least one element selected from V, Nb, Ta, Ti, Zr, Hf, Co or Ni, if necessary. The alloy is produced by mixing the above mentioned components and pressurizing them in an Fe matrix, then sintering the pressurized mixture at 1150.degree. C. to 1260.degree. C. for 60 min. and reheating after sintering. This alloy has wear and heat resistance and can be utilized as valve seats for internal combustion engines in automotive vehicles.

Abstract: The present invention relates to a method of sintering ceramics and ceramics obtained by said method. According to the present invention, the synthesis and sintering of ceramics can be simultaneously carried out by utilizing the reaction heat generated when at least one metallic element selected from metallic elements of IIb, IVb, Vb and VIb groups of the Periodic Table is combined with at least one nonmetallic element such as B, C N and Si without heat or by preliminarily heating the ceramics at temperatures remarkably lower than the usual sintering temperature ceramics thus-produced are superior in abrasion resistance and corrosion resistance.

Abstract: A method for producing an anisotropic rare earth magnet is improved by applying compressing stress on a free surface of an compacted material at the time of extruding the compacted material in order to prevent forming cracks, and improved by using a double action punch provided with a core punch and a sleeve punch so as to mold a compacted material and extrude the compacted material into the anisotropic magnet material in a single heat process continuously.

Abstract: Wear resistant powder sintered alloy of excellent corrosion resistance comprising a hard alloy containing from 15 to 95% of a hard phase composed of a M.sub.3 B.sub.2 phase (M represents Ni or Co, Cr, Mo or W) structure in the matrix, wherein the hard alloy contains, on the weight basis, 0.5-9.0% of B, 14.0-35.0% of Cr, 14.0-50.0% of one or more of Mo and W, up to 3.5% of Si, 0.5-20.0% of one or more of Cu, Ag, Au and Pt and the balance of one or more of Ni and Co and inevitable impurities, and the matrix has a noble corrosion potential.The novel abrasion resistant sintered powdery alloy has excellent corrosion resistance to corrosive gases such as hydrogen, SO.sub.2 and NOx which are often released from molding processes for plastics, rubbers, etc.

Abstract: A method for manufacturing ceramic/metal or ceramic/ceramic composite articles is disclosed. The articles can be useful for the production of aluminum in fused salt electrolysis cells, as armour plates for the protection against projectiles, cutting tools, or in abrasion resistance applications. The temperature slope of the process if optimized such that one of the reactants in the manufacturing proceeds through peritectic decomposition at a heating rate of low temperature increase for desirably uniform temperature distribution over the reaction mixture. Then the temperature increase is greatly elevated to obtain a reaction sintering condition for avoiding grain growth of undesired reaction products. Elevated temperature reaction sintering conditions can be maintained to decompose undesired components before they are entrapped by the reaction product.

Abstract: Substantially dense, void-free ceramic-metal composites are prepared from components characterized by chemical incompatibility and non-wetting behavior. The composites have a final chemistry similar to the starting chemistry and microstructures characterized by ceramic grains similar in size to the starting powder and the presence of metal phase. A method for producing the composites requires forming a homogeneous mixture of ceramic-metal, heating the mixture to a temperature that approximates but is below the temperature at which the metal begins to flow and presssing the mixture at such pressure that compaction and densification of the mixture occurs and an induced temperature spike occurs that exceeds the flowing temperature of the metal such that the mixture is further compacted and densified. The temperature spike and duration thereof remains below that at which significant reaction between metal and ceramic occurs. The method requires pressure of 60-250 kpsi employed at a rate of 5-250 kpsi/second.

Abstract: Disclosed are a method of and a device for manufacturing Nd-Fe-B alloy magnet materials, and in particular, for manufacturing an integral, columnar-ring-shaped Nd-Fe-B magnet which is multi-pole-magnetized along the circumference thereof and which is used as the rotor magnet of a high-efficiency stepping motor. According to the method, a green compact or a densified compact is first prepared from a selected flake or a powder material composed of amorphous and/or fine-crystallized particles obtained through rapid quenching of the molten alloy. It is then provided with magnetic anisotropy through plastic deformation effected radially inwardly along substantially the entire periphery of the compact initially deformed to receive a mandrel-core, and maintained at a temperature of 600 to 850 degrees C. Subsequently, the deformed body is magnetized with the desired radial or polar magnetization pattern.

Abstract: High density compacts are made by providing a compactable particulate combination of Class 1 metals selected from at least one of Ag, Cu and Al, with material selected from at least one of CdO, SnO, SnO.sub.2, C, Co, Ni, Fe, Cr, Cr.sub.3 C.sub.2, Cr.sub.7 C.sub.3, W, WC, W.sub.2 C, WB, Mo, Mo.sub.2 C, MoB, Mo.sub.2 B, TiC, TiN, TiB.sub.2, Si, SiC, Si.sub.3 N.sub.4, usually by mixing powders of each, step (1); uniaxially pressing the powders to a density of from 60% to 95%, to provide a compact, step (2); hot densifying the compact at a pressure between 352 kg/cm.sup.2 (5,000 psi) and 3,172 kg/cm.sup.2 (45,000 psi) and at a temperature from 50.degree. C. to 100.degree. C. below the melting point or decomposition point of the lower melting component of the compact, to provide densification of the compact to over 97% of theoretical density; step (3); and cooling the compact, step (4).

Abstract: Anisotropic hot-worked permanent magnets are made from an R-T-B alloyed powder to which is added a combination internal lubricant including a carbon-based material such as graphite and a glass material such as glass from the B.sub.2 O.sub.3 -SiO.sub.2 BiO.sub.3 glass system. The internal lubricant provides improved formability during the hot-working step, such as die-upsetting, and provides finished magnet products wherein the individual grains are more uniformly plastically deformed throughout the product.

Abstract: A creep-resistant alloy having a tiered structural arrangement of one or several refractory metals Mo, W, Nb, Ta, V, Cr containing certain doping agents, as well as a process for producing the same. The special doping agents are compounds and/or mixed phases of such compounds selected from the group of oxides, nitrides, carbides, borides, silicates or aluminates having a melting point higher than 1500.degree. C. The size of their grains is .ltoreq.1.5 .mu.m, their proportion in the alloy is comprised between 0.005 and 10% by weight. Unlike in the known state of the art, the use of porassium as doping agent is avoided in this alloy. A good reproducible consolidation and in particular high densities during sintering can thus be obtained. Furthermore, this alloy has better ambient temperature, heat and creep resistance properties than known alloys of refractory metal with a tiered structual arrangement.

Abstract: A method of making high energy Nd-Fe-B magnets having a mass less than 30 grams wherein an alloy of said materials having a grain size less than that desired in the finished magnet is first prepared and subsequently hot worked to the desired configuration with increased magnetic properties and density by introducing into a cavity formed by a die and punch a Nd-Fe-B alloy powder having a particle size of from 45 .mu.m to 250 .mu.m and a grain size of from 100 to 1500 angstroms, compressing the powder at a temperature of from about 550.degree. C. to 750.degree. C. under a die-punch pressure of at least 10 kpsi under a vacuum of less than 200 millitorr to achieve a permanent magnet having a remanence of at least 7 kilogauss.

Abstract: A composite tool with a higher bonding strength and higher heat resistance is provided comprising an insert of a hard material such as composite diamond or BN compacts and a support of a hard metal or alloy such as steel and cemented carbides, having a larger volume than the insert, the insert and support being bonded by friction welding through an interlayer of a high strength metal or alloy such as Co and Ni with a thickness of at most 1 mm.

Abstract: An aluminum based metal matrix composite is produced from a charge containing a rapidly solidified aluminum alloy and particles of a reinforcing material present in an amount ranging from about 0.1 to 50 percent by volume of the charge. The charge is ball milled energetically to enfold metal matrix material around each of the particles while maintaining the charge in a pulverulant state. Upon completion of the ball milling step, the charge is consolidated to provide a powder compact having a formable, substantially void free mass. The compact is especially suited for use in aerospace, automotive, electronic, wear resistance critical components and the like.

Abstract: Dense, finely grained composite materials comprising one or more ceramic phase or phase and one or more metallic and/or intermetallic phase or phases are produced by combustion synthesis. Spherical ceramic grains are homogeneously dispersed within the matrix. Methods are provided, which include the step of applying mechanical pressure during or immediately after ignition, by which the microstructures in the resulting composites can be controllably selected.

Abstract: A metal-metal matrix composite magnet including a magnetic material such as a neodymium-iron-boron magnetic phase bonded by a metal matrix, preferably copper an a method of making the magnet which involves plating a thin metal layer, for example, a layer having a thickness of less than 1000 angstrom average, from a magnetic phase, pressing the powder, with or without magnetic alignment, into the desired shape and then sintering the pressed powder at a temperature below about 400.degree. C.

Abstract: A powder of at least one of TiB.sub.2, ZrB.sub.2 and HfB.sub.2 is mixed with at least one of Ti, Zr, Hf, TiB, ZrB and HfB, or with at least one of Ti, Zr, Hf, TiB, ZrB and HfB and a powder of boron, to prepare a mixed powder which can form a sintered product having a boron content of 65 to 67 atom %. Alternatively, a powder of at least one of Ti, Zr, Hf, TiB, ZrB and HfB is mixed with a powder of boron to prepare the mixed powder. The mixed powder may further contain up to a maximum of 30% by weight of a powder of AlN. Then, the mixed powder is sintered to make metal diboride ceramics. The lower-melting metal or compound which the mixed powder contains melts to form a liquid phase and enables the manufacture of a sintered product of high density by a customary sintering operation employing a low temperature. The sintered product having a boron content of 65 to 67 atom % consists solely of metal diboride crystals having a structure of the hexagonal system.

Abstract: A method for sintering and forming powder is disclosed. In this method a high voltage of 3 KV or more is applied to a mold filled with powder using an electrode which maintains a high current of 50 KA cm.sup.-2 or greater for a period of time from 10 to 500 microseconds. A device for practicing this method is also disclosed.

Abstract: The machinability characteristics of P/M ferrous sintered compacts are improved when the compact is prepared from a ferrous powder having a maximum particle size less than about 300 microns, and from at least about 0.01 weight percent of a boron nitride powder comprising agglomerates of irregular-shaped, submicron particles.

Abstract: The present invention relates to porous powder metal (P/M) parts having improved dynamic properties such as impact and fatigue strength. These properties are achieved by the use of finer metal powders.

Abstract: A method is disclosed of hot working a magnetically soft cast crystalline material containing grains of RE.sub.2 TM.sub.14 B and an RE metal, rich intergranular second phase into anisotropic permanent magnet bodies.

Abstract: Magnetically isotropic, fine grain, RE.sub.2 Fe.sub.4 B phase containing particulate material is hot pressed to full density and bonded to a metal backing layer of desired shape and composition. Additionally, if desired, the fully dense isotropic material can be further deformed in a direction lateral to the press direction so as to strain the particles to align the preferred magnetic axes of the crystal grains therein and thus form a laminate of a magnetically anisotropic magnet layer bonded to a metal backing layer.

Abstract: New Iron-Neodymium-Boron base alloys containing hafnium diboride, zirconium diboride and titanium diboride are disclosed. The alloys are subjected to rapid solidification processing technique which produces cooling rates between 10.sup.5 to 10.sup.7 .degree.C.second. The as-quenched filament, ribbon or particulate, powder etc. consists predominantly of a single amorphous phase. The amorphous powder is heat treated above the crystallization temperature into microcrystalline powder which is subsequently ground into ultrafine particles with average size less than 5 microns by attritor or hammer mill. The ultrafine powder particles are simultaneously aligned and cold compacted by the combined action of an applied magnetic field and uniaxial pressure. The green compacts containing particles with mostly aligned grains with their easy magnetization axes parallel to the applied field direction are sintered into bulk forms.