Abstract: The disclosure relates generally to recovering bond coat materials and barrier coat materials from co-mingled mixtures of bond coat and barrier coat materials (e.g., plasma overspray waste), and from mixtures of co-mingled bond coat and barrier coat materials stripped from a substrate. The disclosure also relates to recovering rare earth elements (e.g., yttrium) from a barrier coat of the co-mingled plasma overspray waste or mixture of co-mingled bond coat and barrier coat materials stripped from the substrate.

Abstract: High-purity erbium having a purity of 5N or higher excluding rare earth elements and gas components, and containing Al, Fe, Cu, and Ta each in an amount of 1 wtppm or less, W in an amount of 10 wtppm or less, carbon in an amount of 150 wtppm or less, alkali metals and alkali earth metals each in an amount of 1 wtppm or less, other transition metal elements in a total amount of 10 wtppm or less, and U and Th as radioactive elements each in an amount of 10 wtppb or less. An object of this invention is to provide a method of highly purifying erbium, which has a high vapor pressure and is difficult to refine in a molten state, as well as technology for efficiently and stably providing high-purity erbium obtained with the foregoing method, a sputtering target made of high-purity erbium, and a metal gate film having high-purity erbium as a main component thereof.

Abstract: Provided herein are materials that can achieve up to 14% hydrogen absorption by weight in ambient conditions, which is a marked improvement over the hydrogen absorption values found in the prior art. Further provided are experimental conditions necessary to produce these materials. In order to produce the hydrogen storage material, a transition metal (or Lithium) is vaporized in a pi bond gas in conditions that permit only a few bonding collisions to occur between the vaporized transition metal atoms and pi bond gas molecules before the resulting bonded material is collected.

Abstract: A carbothermic reduction method is provided for reducing a La-, Ce-, MM-, and/or Y-containing oxide in the presence of carbon and a source of a reactant element comprising Si, Ge, Sn, Pb, As, Sb, Bi, and/or P to form an intermediate alloy material including a majority of La, Ce, MM, and/or Y and a minor amount of the reactant element. The intermediate material is useful as a master alloy for in making negative electrode materials for a metal hydride battery, as hydrogen storage alloys, as master alloy additive for addition to a melt of commercial Mg and Al alloys, steels, cast irons, and superalloys; or in reducing Sm2O3 to Sm metal for use in Sm—Co permanent magnets.

Abstract: A method for preparing R5X4 alloy materials where R is a rare earth element selected from one or more of La, Ce, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Lu, Sc, and Y and X represents a non-rare earth alloying element such as silicon, germanium, tin, lead, gallium, indium and mixtures thereof. The method involves carbothermically reducing amounts of a rare earth element-containing oxide, an alloying element-containing oxide and/or alloying element in elemental or alloy form, and carbon at elevated temperature to form an R5X4 alloy material, which is melted, solidified, and optionally heat treated. Such a method provides an economical and efficient technique of configuring magnetic refrigerant, magnetostrictive and magnetoresistive alloys and products.

Abstract: The present invention relates to new compositions of matter, particularly metals and alloys, and methods of making such compositions. The new compositions of matter exhibit long-range ordering and unique electronic character.

Abstract: A method for recovering at least one rare earth element from a phosphor is presented. The method includes a halogenation step (a) and a reduction step (b). The phosphor is first halogenated in a molten salt to convert at least one rare earth constituent contained therein to a soluble rare earth halide. Then, the rare earth halide in the molten salt can be reduced, to convert the rare earth halide to a rare earth element in its elemental state. A method for individually recovering multiple rare earth elements from a phosphor is also presented.

Abstract: A method for recovering at least one rare earth element from a phosphor is presented. The method includes a halogenation step (a) and a reduction step (b). The phosphor is first halogenated in a molten salt to convert at least one rare earth constituent contained therein to a soluble rare earth halide. Then, the rare earth halide in the molten salt can be reduced, to convert the rare earth halide to a rare earth element in its elemental state. A method for individually recovering multiple rare earth elements from a phosphor is also presented.

Abstract: Provided are a method for manufacturing high-purity erbium, wherein crude erbium oxide is mixed with reducing metal, erbium is reduced and distilled by heating the mixture in a vacuum, and the distillate is melted in an inert atmosphere to obtain high-purity erbium; and high-purity erbium, wherein the purity excluding rare-earth elements and gas components is 4 N or higher and the oxygen content is 200 wtppm or less. An object of this invention is to provide a method of highly purifying erbium, which has a high vapor pressure and is difficult to be refined in a molten metal state, as well as technology for efficiently and stably providing high-purity erbium obtained with the foregoing method, a sputtering target composed of high-purity erbium, and a metal gate film having high-purity erbium as a main component.

Abstract: The present invention relates to new compositions of matter, particularly metals and alloys, and methods of making such compositions. The new compositions of matter exhibit long-range ordering and unique electronic character.

Abstract: Provided is a method of producing high purity ytterbium, wherein the high purity ytterbium is obtained by reducing crude ytterbium oxide in a vacuum with reducing metals composed of metals having a low vapor pressure, and selectively distilling ytterbium. Additionally provided are methods of achieving the high purification of ytterbium which has a high vapor pressure and is hard to refine in a molten state, and high purity ytterbium obtained thereby. Further provided is technology for efficiently and stably obtaining a sputtering target made of high purity material ytterbium, and a thin film for metal gates containing high purity material ytterbium.

Abstract: Provided herein are materials that can achieve up to 14% hydrogen absorption by weight in ambient conditions, which is a marked improvement over the hydrogen absorption values found in the prior art. Further provided are experimental conditions necessary to produce these materials. In order to produce the hydrogen storage material, a transition metal (or Lithium) is vaporized in a pi bond gas in conditions that permit only a few bonding collisions to occur between the vaporized transition metal atoms and pi bond gas molecules before the resulting bonded material is collected.

Abstract: An alloy having a formula: (Zr1Ti)100-x-u(Cu100-aNia)XAlu wherein X, U and a are in atomic percentages in the following ranges: 37?x?48, 3?u?14, and 3?a?30.

Abstract: The present invention provides a novel process for preparation of inorganic colourants from mixed rare earth compounds, which are directly obtained from the ore industry, without undergoing any separation, thereby enabling a cost reduction to the extend of 10-100 times. Colors ranging from brown, blue and green can be obtained by suitable doping with other metal ions.

Abstract: Rare earth magnet scrap and/or sludge is remelted for reuse. Once a rare earth-free magnet-constituent metal feed is loaded in a melting furnace and heated into a melt, a rare earth-containing metal feed and the rare earth magnet scrap and/or sludge are added to the melt, a particulate flux of an alkali metal, alkaline earth metal or rare earth metal halide and having an average particle size of 1-50 ?m, preferably wrapped in a metal foil, is added to the melt, and the resulting mixture is melted, from which an alloy ingot is obtained. The valuable elements in the scrap and/or sludge can be recycled. Better separation between the slag and the molten metal ensures that the ingot is obtained from the melt in a high yield.

Abstract: A treatment apparatus (10) includes a liquid reactant metal containment vessel (11) for containing a first liquid reactant metal and isolating the reactant metal from the atmosphere. A release chamber (14) is adapted to receive the first liquid reactant metal from the containment vessel (11) and a submerging arrangement (21) is adapted to dunk or submerge a container (46) of feed material into the liquid reactant metal and move the container to a release location within the release chamber (14). Relatively light materials rising from the submerged container (46), including unreacted feed material, intermediate reaction products, and perhaps final reaction products collect in a collection area (60) having an upper surface defined by an upper surface of the release chamber (14).

Abstract: A hydrogen storage bed system which includes a pressure container, a hydrogen storage alloy disposed within the pressure container, and an integrated thermal management system integrally disposed within the pressure container. The integrated thermal management system includes heat generation means, cooling means adapted to use an aerosol coolant, and heat distribution means.

Abstract: A hydrogen storage bed system which includes a pressure container, a hydrogen storage alloy disposed within the pressure container, and an integrated thermal management system integrally disposed within the pressure container. The integrated thermal management system includes heat generation means, cooling means, and heat distribution means.

Abstract: Rare earth alloy compositions, such as the neodymium iron boron (NdFeB) alloy are made by a Reduction-Melting process. The Reduction-Melting process comprises preparing a primary electrode containing at least one compound or metal to be reduced to form a refined metal or metal alloy ingot; placing the electrode in an electroslag refining furnace; passing a current through the electrode into a molten flux or slag to melt the electrode; reducing the metal or compound in the slag while forming an oxide by-product; collecting melted metal or metal alloy droplets falling through the slag; forming an ingot of the metal or metal alloy from the melted droplets; and collecting the solid oxide byproducts in the slag.

Abstract: A method for reducing Carbon contained in hydrogen storage alloys recovered from negative electrodes of nickel/hydrogen storage alloy secondary batteries of misch metal and alloys thereof as raw materials of hydrogen storage alloys for negative electrodes of nickel/hydrogen secondary batteries by adding titanium or zirconium or oxides of these elements, and melting in an inert gas atmosphere or in vacuum.

Abstract: A dual zone chemical reactor continuously processes metal-containing materials while regenerating and circulating a liquid carrier. The starting materials are fed into a first reaction zone of a vessel containing a molten salt carrier. The starting materials react to form a metal product and a by-product that dissolves in the molten salt that flows to a second reaction zone in the reaction vessel. The second reaction zone is partitioned from, but in fluid communication with, the first reaction zone. The liquid carrier continuously circulates along a pathway between the first reaction zone and the second reaction zone. A reactive gas is introduced into the second reaction zone to react with the reaction by-product to generate the molten salt. The metal product, the gaseous waste products, and the excess liquid carrier are removed without interrupting the operation of the reactor.

Abstract: A process is disclosed for the calcium reduction of rare earth fluorides, especially neodymium and/or praseodymium fluorides, in a minimum volume stirred molten calcium chloride reaction medium that produces high yield, high quality rare earth alloy with a calcium fluoride byproduct that can be recycled to generate more rare earth fluoride starting material.

Abstract: Rare earth-transition metal (e.g., iron) scrap (e.g., Nd-Fe-B scrap) is flux (slag) remelted to reduce tramp non-metallic impurities, such as oxygen and nitrogen, and metallic impurities, such as Li, Na, Al, etc., picked up by the scrap from previous fabrication operations. The tramp impurities are reduced to concentrations acceptable for reuse of the treated alloy in the manufacture of end-use articles, such as permanent magnets. The scrap is electroslag or inductoslag melted using a prefused, rare earth fluoride-bearing flux of CaF.sub.2, CaCl.sub.2 or mixtures thereof or the slag resulting from practice of the thermite reduction process to make a rare earth-iron alloy.

Abstract: Rare earth-transition metal (e.g. iron) scrap (e.g. Nd-Fe-B scrap) is melted to reduce the levels of tramp oxygen and nitrogen impurities therein. The tramp impurities are reduced in the melt by virtue of the reaction of the tramp impurities and the rare earth to form dross on the melt. The purified melt is separated from the dross for reuse. The oxygen and nitrogen of the melt are reduced to levels acceptable for reuse of the treated alloy in the manufacture of end-use articles, such as permanent magnets.

Abstract: In a metallothermic process for reducing rare earth metal salts to produce pure rare earth metals and metal alloys, e.g. neodymium or neodymium/iron alloy for use in manufacturing neodymium/boron/iron permanent magnets, including adding pure metallic iron, such as iron flake, to a mixture of metal salt, such as neodymium chloride, and a reducing metal source, such as calcium/magnesium alloy, heating in a crucible in a preheated high temperature furnace with stirring to a temperature of 900 degrees C. under a flow of argon, separating the metal from the salt formed, and purifying the metal via distillation.