Sumitomo Special Metals Co., Ltd.

Neomax Co., Ltd.

Hitachi Metals, Ltd.

Neomax Materials Co., Ltd.

Takeshi Nishiuchi

Fumiaki Kikui

Kohshi Yoshimura

Yoshimi Tochishita

Satoshi Hirosawa

Noriyuki Nozawa

Hirokazu Kanekiyo

Nobuhiro Misumi

Masahiro Asano

Tomohito Maki

Mitsuo Kizawa

Ikuo Shimamoto

Takahiro Isozaki

Futoshi Kuniyoshi

Rintaro Ishii

Teppei Satoh

Katsunori Bekki

Ryosuke Kogure

Shuji Tsujimoto

Atsushi Kikugawa

Toshio Miyoshi

Tsunehiro Kawata

Kazuaki Okuno

Kazumitsu Sato

Yasutaka Shigemoto

Takayuki Kanda

Yoshimura Kohshi

To provide an R-T-B based sintered magnet including R: 27.5 to 34.0% by mass, RH: 2 to 10% by mass, B: 0.89 to 0.95% by mass, Ti: 0.1 to 0.2% by mass, Ga: 0.3 to 0.7% by mass, Cu: 0.07 to 0.50% by mass, Al: 0.05 to 0.50% by mass, M (M is Nb and/or Zr): 0 to 0.3% by mass, balance T, and inevitable impurities, the following inequality expressions (1), (2), and (3) being satisfied:[T]&#x2212;72.3([B]&#x2212;0.45[Ti])&#x3e;0&#x2003;&#x2003;(1)([T]&#x2212;72.3([B]&#x2212;0.45[Ti]))/55.85&#x3c;13[Ga]/69.72&#x2003;&#x2003;(2)[Ga]&#x2265;[Cu]&#x2003;&#x2003;(3).

R-T-B-based sintered magnet and method for producing same

A sintered R-T-B based magnet composition includes: R: not less than 27 mass % and not more than 37 mass % (R is at least one rare-earth element which always includes at least one of Nd and Pr), B: not less than 0.75 mass % and not more than 0.97 mass %, Ga: not less than 0.1 mass % and not more than 1.0 mass %, Cu: not less than 0 mass % and not more than 1.0 mass %, and T: 61.03 mass % or more (where T is at least one selected from Fe, Co, Al, Mn and Si and always includes Fe, such that the Fe content is 80 mass % or more in the entire T). [T]/[B] is greater than 14.0. An R amount is greater in the surface than in the center, and a Ga amount is greater in the surface than in the center. [T]/[B] in the surface is higher than [T]/[B] in the center.

R-T-B sintered magnet and production method therefor

To provide an R-T-B based sintered magnet having high Band high Hwhile suppressing the content of Dy. Disclosed is an R-T-B based sintered magnet represented by the formula: uRwBxGayCuzAlqM(balance)T, where R is composed of light rare-earth element(s) RL and heavy rare-earth element(s) RH, RL is Nd and/or Pr, RH is Dy and/or Tb, T is Fe, and 10% by mass or less of Fe is capable of being replaced with Co, M is Nb and/or Zr, inevitable impurities being included, and u, w, x, y, z and q are expressed in terms of % by mass; RH accounts for 5% by mass or less of the R-T-B based sintered magnet, 0.4&#x2264;x&#x2264;1.0, 0.07&#x2264;y&#x2264;1.0, 0.05&#x2264;z&#x2264;0.5, 0&#x2264;q&#x2264;0.1, and 0.100&#x2264;y/(x+y)&#x2264;0.340; v=u&#x2212;(6&#x3b1;+10&#x3b2;+8&#x3b3;), where the amount of oxygen (% by mass) is &#x3b1;, the amount of nitrogen (% by mass) is &#x3b2;, and the amount of carbon (% by mass) is &#x3b3;; and v and w satisfy the following inequality expressions: v&#x2264;32.0, 0.84&#x2264;w&#x2264;0.93, and &#x2212;12.5w+38.75&#x2264;v&#x2264;&#x2212;62.5w+86.125.

R-T-B based sintered magnet

An R&#x2014;Fe&#x2014;B based porous magnet according to the present invention has an aggregate structure of NdFeB type crystalline phases with an average grain size of 0.1 &#x3bc;m to 1 &#x3bc;m. At least a portion of the magnet is porous and has micropores with a major axis of 1 &#x3bc;m to 20 &#x3bc;m.

R&#x2014;Fe&#x2014;B porous magnet and method for producing the same

R-Fe-B porous magnet and method for producing the same

An R&#x2014;Fe&#x2014;B based rare-earth alloy powder with a mean particle size of less than about 20 &#x3bc;m is provided and compacted to make a powder compact. Next, the powder compact is subjected to a heat treatment at a temperature of about 550&#xb0; C. to less than about 1,000&#xb0; C. within hydrogen gas, thereby producing hydrogenation and disproportionation reactions (HD processes). Then, the powder compact is subjected to another heat treatment at a temperature of about 550&#xb0; C. to less than about 1,000&#xb0; C. within either a vacuum or an inert atmosphere, thereby producing desorption and recombination reactions and obtaining a porous material including fine crystal grains, of which the density is about 60% to about 90% of their true density and which have an average crystal grain size of about 0.01 &#x3bc;m to about 2 &#x3bc;m (DR processes). Thereafter, the porous material is subjected to yet another heat treatment at a temperature of about 750&#xb0; C. to less than about 1,000&#xb0; C. within either the vacuum or the inert atmosphere, thereby further increasing its density to about 93% or more of their true density and making an R&#x2014;Fe&#x2014;B based microcrystalline high-density magnet.

R-Fe-B microcrystalline high-density magnet and process for production thereof

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

A surface treating process according to the present invention, a vapor deposited film is formed from an easily oxidizable vapor-depositing material on the surface of a work by evaporating the vapor-depositing material in a state in which the vapor deposition controlling gas has been supplied to at least zones near a melting/evaporating source and the work within a treating chamber. Thus, the vapor deposited film can be formed stably on the surface of a desired work without requirement of a long time for providing a high degree of vacuum and without use of a special apparatus. In addition, the use of the surface treating process ensures that a corrosion resistance can be provided to a rare earth metal-based permanent magnet extremely liable to be oxidized, without degradation of a high magnetic characteristic of the magnet. A surface treating apparatus according to the present invention includes a melting/evaporating source for melting and evaporating a wire-shaped vapor-depositing material containing a vapor deposition controlling gas, and a member for retaining a work on which the vapor-depositing material is deposited. The melting/evaporating source and the work retaining member are disposed in a treating chamber of the surface treating chamber. The apparatus further includes a vapor-depositing material supply means for supplying the wire-shaped vapor-depositing material containing the vapor deposition controlling gas to the melting-evaporating source.

Surface treating apparatus

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

A process for treating surfaces of rare earth metal-based permanent magnets, comprising removing an oxide layer formed on a surface of each of the permanent magnets using a blasting apparatus. The apparatus comprises a tubular barrel formed of a mesh net for accommodation of work pieces and supported circumferentially outside a center axis of a support member rotatable about the center axis, and an injection nozzle disposed to inject a blast material against the work pieces from the outside of the tubular barrel, wherein at least one of the tubular barrel and the support member is detachably mounted. The process further comprises removing the tubular barrel or the support member from the blasting apparatus and attaching the tubular barrel or the support member to a vapor deposited film forming apparatus, where a metal film is formed on the surface of each of the permanent magnets by a vapor deposition process.

Method for treating surfaces of rare earth metal-based permanent magnets

A dry surface treating apparatus of the present invention comprises, within a treating chamber, a surface-treating material supply section and a tubular barrel having a porous peripheral surface for accommodating a work piece, to treat a surface of the work piece while rotating the tubular barrel horizontally arranged about a horizontal rotational axis, wherein the tubular barrel has a slide stop for stopping a slide of the accommodated work piece along an inner peripheral surface of the tubular barrel due to rotation of the tubular barrel. According to the dry surface treating apparatus of the invention, because the work piece is inverted of surfaces within the tubular barrel, the time the work piece at each surface faces the surface-treating material supply section is made equivalent. Consequently, it is possible to provide even deposited-film formation or surface treatment to the opposite surfaces of a work piece, particularly, a rare earth metal-based permanent magnet in a plate or bow form.

Dry surface treating apparatus and dry surface treating method using the same apparatus

A rare earth metal-based permanent magnet has a film layer formed substantially of only a fine metal powder on a metal forming the surface of the magnet. The rare earth metal-based permanent magnet having the film layer on its surface is produced in the following manner: A rare earth metal-based permanent magnet and a fine metal powder forming material are placed into a treating vessel, where both of them are vibrated and/or agitated, whereby a film layer made of a fine metal powder produced from the fine metal powder producing material is formed on a metal forming the surface of the magnet. Thus, the formation of a corrosion-resistant film such as plated film can be achieved at a high thickness accuracy by forming an electrically conductive layer uniformly and firmly on the entire surface of the magnet without use of a third component such as a resin and a coupling agent.

Rare earth metal-based permanent magnet, and process for producing the same

With the deposited-film forming apparatus according to the first embodiment of the present invention, the distance between the tubular barrel and the evaporating section can be varied, unlike the prior art deposited-film forming apparatus and hence, the efficient formation of the deposited film on the surface of each of the work pieces accommodated in the tubular barrel and the inhibition of the softening of the formed film can be achieved simultaneously. Therefore, it is possible to inhibit the damaging of the deposited film formed on the surface of each of the work pieces and the production of projections on the deposited film, and to form a deposited film at a high quality in respect of a corrosion resistance and the like and at low cost. With the deposited-film forming apparatus according to the second embodiment of the present invention, the distance between the accommodating section defined in the tubular barrel and the evaporating section can be varied and hence, this deposited-film forming apparatus also exhibits an effect similar to that in the deposited-film forming apparatus according to the first embodiment of the present invention.

Deposited-film forming apparatus

An electroplating device including an anode inserted through and disposed in a hole provided in a work and communicating with the outside, and a member for rotating the work about its center axis and supplying a plating electric current to the work. Alternatively, a separate member may supply the plating electric current to the work. A plating solution in the hole in the work may be allowed to flow. Thus, a uniform plated film can be formed on both of the outer and inner surfaces of the work having the communicating with the outside such as a ring-shaped work, of which a ring-shaped bonded magnet is representative, by using the electroplating device.

Growing community of inventors

Osaka, Japan

Takeshi Nishiuchi