A magnetic body of the coil component contains, as soft magnetic alloy grains, first grains whose alloy components are substantially Fe, Si, and Cr, and second grains which contain, as alloy components, Fe, Si, and an element other than Si or Cr that oxidizes more easily than Fe; the average grain size of the second grains is smaller than the average grain size of the first grains; the first grains have, on their surface, an amorphous oxide film containing Si and Cr; the second grains have, on their surface, a crystalline oxide layer containing the element other than Si or Cr that oxidizes more easily than Fe; and the crystalline oxide forms adhesion parts, each contacting a multiple number of the first grains via the amorphous oxide film thereof and coupling or bridging the multiple number of the first grains. The coil component can offer improved mechanical strength.

Provided are methods and devices for forming high nitrogen steel. The processes include heating a steel precursor to a temperature that transforms the steel into an austenite of FCC wherein the heating is in a nitrogen containing atmosphere. After an optional nitrogen uptake time, the precursor is further heated to a temperature above the T.sub.γN of the steel yet below the melting point of the steel thereby preserving a solid and creating a solid solution of nitrogen. The second temperature is optionally maintained for a nitride conversion time, optionally wherein the nitride conversion time is too short to result in sintering of the steel. The process further includes rapid quenching of the precursor powder to maintain the nitrogen solid solution and prevent nitride formation thereby forming a high nitrogen steel with little to no nitride content and including nitrogen in solid solution.

A magnet structure includes columnar grains of rare earth permanent magnet phase aligned in a same direction and arranged to form bulk anisotropic rare earth alloy magnet having a boundary defined by opposite ends of the columnar grains and lacking triple junction regions, and rare earth alloy diffused onto opposite ends of the bulk anisotropic rare earth alloy magnet.

Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to unique powder feedstocks such as Tantalum, Yttrium Stabilized Zirconia, Aluminum, water atomized alloys, Rhenium, Tungsten, and Molybdenum. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.

The present disclosure discloses a preparation method of a multi-functional marine engineering alloy. Through the coupling of a multi-principal alloy structure, structural entropy, and temperature and powder metallurgy and heat treatment, mutual solubility between elements and free energy of an alloy system are regulated, Cu grain boundary segregation is eliminated, and uniform and dispersed nano-precipitation of the anti-fouling element Cu in corrosion-resistant and high-plasticity multi-principal alloys is realized. The preparation method is simple and controllable to operate, and the prepared material has plasticity higher than 75%, high yield strength, excellent corrosion resistance and anti-fouling property, and has important application prospects in the field of marine engineering.

Disclosed herein are embodiments of mechanically alloyed powder feedstock and methods for spheroidizing them using microwave plasma processing. The spheroidized powder can be used in metal injection molding processes, hot isostatic processing, and additive manufacturing. In some embodiments, mechanical milling, such as ball milling, can be used to prepare high entropy alloys for microwave plasma processing.

A method includes depositing a layer of alloy particles including rare earth permanent magnet phase above a substrate, laser scanning the layer while cooling the substrate to melt the particles, selectively initiate crystal nucleation, and promote columnar grain growth in a same direction as an easy axis of the rare earth permanent magnet phase. The method also includes repeating the depositing and scanning to form bulk anisotropic rare earth alloy magnet with aligned columnar grains.

The powder mixture for powder metallurgy includes a raw material powder, a binder, and a graphite powder, where the raw material powder contains an iron-based powder in a content of 90 mass % or more of the raw material powder, the graphite powder has an average particle size of less than 5 μm, a ratio in mass of the binder to the sum the raw material powder and the graphite powder is 0.10 mass % to 0.80 mass %, a ratio of mass of the graphite powder to the sum of mass of the raw material powder and mass of the graphite powder is 0.6 mass % to 1.0 mass %, surface of the raw material powder is covered with at least a part of the binder, and surface of the binder covering the surface of the raw material powder is covered with at least a part of the graphite powder.

Carbon fiber reinforced steel matrix composites have carbon fiber impregnated in the steel matrix and chemically bonded to the steel. Chemical bonding is shown by the presence of a unique amorphous carbon layer at the carbon fiber/steel interface, and by canting of steel crystal edges adjacent to the interface. Methods for forming carbon fiber reinforce steel composites include sintering steel nanoparticles around a reinforcing carbon fiber structure, thereby chemically bonding a sintered steel matrix to the carbon fiber. This unique bonding likely contributes to enhanced strength of the composite, in comparison to metal matrix composites formed by other methods.

Methods for fabricating an interconnect for a fuel cell stack that include providing a protective layer over at least one surface of an interconnect formed by powder pressing pre-alloyed particles containing two or more metal elements and annealing the interconnect and the protective layer at elevated temperature to bond the protective layer to the at least one surface of the interconnect.