Sumitomo Special Metals Co., Ltd.

Neomax Co., Ltd.

Hitachi Metals, Ltd.

Santoku Corporation

Nippon Kagaku Yakin Co., Ltd.

Sumitomo Special Co., Ltd.

Hirokazu Kanekiyo

Satoshi Hirosawa

Toshio Miyoshi

Yasutaka Shigemoto

Takeshi Nishiuchi

Ryo Murakami

Ryosuke Kogure

Yusuke Shioya

Hirokazu Kitayama

Katsunori Bekki

Ikuo Uemoto

Kazuo Ishikawa

A method for producing a rare-earth alloy based binderless magnet according to the present invention includes the steps of: (A) providing a rapidly solidified rare-earth alloy magnetic powder; and (B) compressing and compacting the rapidly solidified rare-earth alloy magnetic powder by a cold process without using a resin binder, thereby obtaining a compressed compact, 70 vol % to 95 vol % of which is the rapidly solidified rare-earth alloy magnetic powder.

Rare earth alloy binderless magnet and method for manufacture thereof

The iron-based rare-earth nanocomposite magnet of the present invention has a composition TQRTiM, where T is Fe or a transition metal element in which Fe is partially replaced by Co and/or Ni; Q is B and/or C; R is at least one rare-earth element including substantially no La or Ce; and M is at least one metal element selected from Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb. x, y, z and n satisfy 5&#x2266;x&#x2266;10 at %, 7&#x2266;y&#x2266;10 at %, 0.1&#x2266;z&#x2266;5 at % and 0&#x2266;n&#x2266;10 at %, respectively. The magnet includes RFeB-type compound phases and &#x3b1; &#x2014;Fe phases forming a magnetically coupled nanocomposite magnet structure. The RFeB-type compound phases have an average crystal grain size of 30 nm to 300 nm and the &#x3b1; &#x2014;Fe phases have an average crystal grain size of 1 nm to 20 nm. The magnet has magnetic properties including a coercivity of at least 400 kA/m and a remanence of at least 0.9 T.

Iron-based rare-earth nanocomposite magnet and method for producing the magnet

A method of making a magnetic alloy material includes the steps of: preparing a melt of an alloy material having a predetermined composition; rapidly cooling and solidifying the melt to obtain a rapidly solidified alloy represented by: FeREATMwhere RE is at least one rare-earth element selected from La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er and Tm and including at least about 90 at % of La; A is at least one element selected from Al, Si, Ga, Ge and Sn; TM is at least one transition metal element selected from Sc, Ti, V, Cr, Mn, Co, Ni, Cu and Zn; and 5 at %&#x2266;a&#x2266;10 at %, 4.7 at %&#x2266;b&#x2266;18 at % and 0 at %&#x2266;c&#x2266;9 at %; and producing a compound phase having an NaZn-type crystal structure in at least about 70 vol % of the rapidly solidified alloy.

Magnetic alloy material and method of making the magnetic alloy material

To make a raw alloy, consisting mostly of amorphous structure, highly productively and at a reduced cost for a nanocomposite magnet, a molten alloy represented by FeRQM(where R is at least one element selected from Pr, Nd, Dy and Tb; Q is B and/or C; M is at least one element selected from Co, Al, Si, Ti, V, Cr, Mn, Ni, Cu, Ga, Zr, Nb, Mo, Ag, Pt, Au and Pb; and 1 at %&#x2266;x&#x3c;6 at %, 15 at %&#x2266;y&#x2266;30 at % and 0 at %&#x2266;z&#x2266;7 at %) is prepared. This molten alloy is rapidly cooled by a strip casting process in which the alloy is fed onto a chill roller, rotating at a peripheral velocity of 3 m/s to less than 20 m/s, at a feeding rate per unit contact width of 0.2 kg/min/cm to 5.2 kg/min/cm. In this manner, an alloy including at least 60 volume percent of amorphous phase can be obtained.

Process for producing, through strip casting, raw alloy for nanocomposite type permanent magnet

A rare-earth alloy powder is obtained by rapidly cooling a melt of an alloy by an atomization process. The alloy has a composition represented by (FeT)QRTiM, where T is at least one of Co and Ni, Q is at least one of B and C, R is at least one of the rare-earth metal elements and yttrium, and M is at least one of Nb, Zr, Mo, Ta and Hf. The mole fractions x, y, z, m and n satisfy 10 at %&#x3c;x&#x2266;25 at %, 6 at %&#x2266;y&#x3c;10 at %, 0.1 at %&#x2266;z&#x2266;12 at %, 0&#x2266;m&#x2266;0.5, and 0 at %&#x2266;n&#x2266;10 at %, respectively. By adding Ti to the alloy, the nucleation and growth of &#x3b1;-Fe during the rapid quenching process can be minimized.

Method for producing nanocomposite magnet using atomizing method

An iron-based rare earth alloy magnet has a composition represented by the general formula: (FeT)QRM, where T is at least one element selected from the group consisting of Co and Ni; Q is at least one element selected from the group consisting of B and C; R is at least one rare earth element substantially excluding La and Ce; and M is at least one metal element selected from the group consisting of Ti, Zr and Hf and always includes Ti. In this formula, the mole fractions x, y, z and m meet the inequalities of: 10 at %&#x3c;x&#x2266;20 at %; 6 at %&#x2266;y&#x3c;10 at %; 0.1 at %&#x2266;z&#x2266;12 at %; and 0&#x2266;m&#x2266;0.5, respectively.

Permanent magnet including multiple ferromagnetic phases and method for producing the magnet

A nanocomposite magnet has a composition represented by (FeT)QRTiM, where T is at least one of Co and Ni, Q is at least one of B and C, R is at least one rare earth element that always includes at least one of Nd and Pr and optionally includes Dy and/or Tb, and M is at least one element selected from the group consisting of Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb. The mole fractions x, y, z, m and n satisfy 10 at %&#x3c;x&#x2266;20 at %, 6 at %&#x2266;y&#x3c;10 at %, 0.5 at %&#x2266;z&#x2266;12 at %, 0&#x2266;m&#x2266;0.5 and 0 at %&#x2266;n&#x2266;10 at %, respectively. The nanocomposite magnet has an oxygen content of at most about 1,500 ppm by mass.

Nanocomposite magnet

A compound for a rare-earth bonded magnet includes a rare-earth alloy powder and a binder. The rare-earth alloy powder includes at least about 2 mass % of Ti-containing nanocomposite magnet powder particles with a composition represented by (FeT)QRM, where T is Co and/or Ni; Q is B with or without C; R is at least one rare-earth element substantially excluding La and Ce; M is at least one metal element selected from Ti, Zr and Hf and always includes Ti; and 10&#x3c;x&#x2266;20 at %; 6&#x2266;y&#x3c;10 at %; 0.1&#x2266;z&#x2266;12 at %; and 0&#x2266;m&#x2266;0.5. The particles include at least two ferromagnetic crystalline phases, in which hard magnetic phases have an average crystal grain size of about 10 nm to about 200 nm, soft magnetic phases have an average crystal grain size of about 1 nm to about 100 nm; and the average crystal grain size of the soft magnetic phases is smaller than that of the hard magnetic phases.

Compound for rare-earth bonded magnet and bonded magnet using the compound

An iron-based rare earth alloy nanocomposite magnet has a composition represented by (FeT)QRTi, where T is Co and/or Ni, Q is B and/or C and R is rare earth element(s) including substantially no La or Ce. x, y, z and m satisfy 10 at %&#x3c;x&#x2266;17 at %, 7 at %&#x2266;y&#x3c;10 at %, 0.5 at %&#x2266;z&#x2266;6 at % and 0&#x2266;m&#x2266;0.5, respectively. The magnet includes crystal grains of an RTQ type compound having an average grain size of 20 nm to 200 nm and a ferromagnetic iron-based boride that exists in a grain boundary between the crystal grains of the RTQ type compound. The boride is dispersed in, or present in the form of a film over, the grain boundary to cover at least partially the surface of the crystal grains of the RTQ type compound.

Iron-based rare earth alloy nanocomposite magnet and method for producing the same

A melt of an alloy, represented (FeT)QRM, where T is Co and/or Ni, Q is B and/or C, R is at least one rare-earth element, M is selected from Al, Si, Ti, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb; 10 at %&#x2266;x&#x2266;35 at %; 2 at %&#x2266;y&#x2266;10 at %; 0 at %&#x2266;z&#x2266;10 at %; and 0&#x2266;m&#x2266;0.5, is prepared. Next, the melt is brought into contact with, and rapidly cooled and solidified by, the surface of a rotating chill roller. The melt is teemed onto a guide member, of which the guide surface defines a tilt angle with a horizontal plane, runs down on the guide surface, and then is fed through at least one tubular hole onto a contact area on the surface of the chill roller.

Method of making rapidly solidified alloy for magnet

A method of making a material alloy for an iron-based rare earth magnet includes the step of forming a melt of an alloy with a composition of (FeT)(BC)RTiM. T is Co and/or Ni; R is at least one element selected from Y (yttrium) and the rare earth elements; and M is at least one element selected from Al, Si, V, Cr, Mn, Ni, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb, wherein the following inequalities are satisfied: 10&#x3c;x&#x2266;25 at %, *6&#x2266;y&#x3c;10 at %, 0.5&#x2266;z&#x2266;12 at %, 0&#x2266;m&#x2266;0.5, 0&#x2266;n&#x2266;10 at % and 0&#x2266;p&#x2266;0.25. Next, the melt is fed onto a shoot with a guide surface tilted at about 1 degree to about 80 degrees with respect to a horizontal plane, thereby moving the melt onto a melt/roller contact region. The melt is then rapidly cooled using a chill roller to make a rapidly solidified alloy including an RFeB phase.

Nanocomposite magnet and method for producing same

An iron-based rare-earth alloy powder includes: a first iron-based rare-earth alloy powder, which has a mean particle size of 10 &mgr;m to 70 &mgr;m and of which the powder particles have aspect ratios of 0.4 to 1.0; and a second iron-based rare-earth alloy powder, which has a mean particle size of 70 &mgr;m to 300 &mgr;m and of which the powder particles have aspect ratios of less than 0.3. The first and second iron-based rare-earth alloy powders are mixed at a volume ratio of 1:49 to 4:1. In this manner, an iron-based rare-earth alloy powder with increased flowability and a compound to make a magnet are provided.

Iron base rare earth alloy powder and compound comprising iron base rare earth alloy powder and permanent magnet using the same

A method of making a material alloy for an iron-based rare earth magnet includes the step of forming a melt of an alloy with a composition of (Fe T ) (B C ) R Ti M . T is Co and/or Ni; R is at least one element selected from Y (yttrium) and the rare earth elements; and M is at least one element selected from Al, Si, V, Cr, Mn, Ni, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb, wherein the following inequalities are satisfied: 10<x&lE;25 at %, *6&lE;y<10 at %, 0.5&lE;z&lE;12 at %, 0&lE;m&lE;0.5, 0&lE;n&lE;10 at % and 0&lE;p&lE;0.25. Next, the melt is fed onto a shoot with a guide surface tilted at about 1 degree to about 80 degrees with respect to a horizontal plane, thereby moving the melt onto a melt/roller contact region. The melt is then rapidly cooled using a chill roller to make a rapidly solidified alloy including an R Fe B phase.

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Kyoto, Japan

Hirokazu Kanekiyo