Provided is a forming method of a metal layer suitable for a 3D printing process. The method includes the steps of (1) providing first metal particles on a substrate to form a first layer; (2) performing a first pre-heat treatment on the first layer; (3) applying an oxide-removing agent on selected first metal particles in the first layer to remove metal oxides; (4) providing second metal particles on the first layer to form a second layer; (5) performing a second pre-heat treatment on the second layer; (6) applying the oxide-removing agent on selected second metal particles in the second layer to remove metal oxides; repeating (1) to (6) until a latent part is formed; performing a first heat treatment on the first and second metal particles of the latent part to form a near shape; and performing a second heat treatment on the near shape to form a sintered body.

A powder for dust cores includes an aggregate of soft magnetic particles, each of which includes a soft magnetic metal particle, and a ferrite film that covers a surface of the soft magnetic metal particle and includes ferrite crystal grains having a spinel structure. A diffraction peak derived from the ferrite crystal grains exists in a powder X-ray diffraction pattern. By a method for producing a powder for dust cores, a raw material powder that includes an aggregate of soft magnetic metal particles is prepared. Furthermore, many ferrite fine particles are formed on a surface of each of the soft magnetic metal particles of the raw material powder. Additionally, the ferrite fine particles are coarsely crystallized through heat treatment to form a ferrite film, which includes ferrite crystal grains having a spinel structure, on the surface of the each of the soft magnetic metal particles.

The purpose of the present invention is to provide: a new magnetic material which exhibits high magnetic stability and excellent oxidation resistance and which can achieve both significantly higher saturation magnetization and lower coercive force than a conventional ferrite-based magnetic material by using a magnetic material obtained by nanodispersing -(Fe,M) phases and M component-enriched phases (here, the M component is at least one component selected from among Zr, Hf, V, Nb, Ta, Cr, Mo, W, Cu, Zn and Si); and a method for producing same. This magnetic material powder exhibits high moldability, and is such that -(Fe, M) phases and M-enriched phases are nanodispersed by chemically reducing M-ferrite nanoparticles, which are obtained by means of wet synthesis, in hydrogen and utilizing phase separation by means of a disproportionation reaction while simultaneously carrying out grain growth. Furthermore, a solid magnetic material is obtained by sintering this powder.

The purpose of the present invention is to provide: a new magnetic material which exhibits high magnetic stability and excellent oxidation resistance and which can achieve both significantly higher saturation magnetization and lower coercive force than a conventional ferrite-based magnetic material by using a magnetic material obtained by nanodispersing -(Fe,M) phases and M component-enriched phases (here, the M component is at least one component selected from among Zr, Hf, V, Nb, Ta, Cr, Mo, W, Cu, Zn and Si); and a method for producing same. This magnetic material powder exhibits high moldability, and is such that -(Fe, M) phases and M-enriched phases are nanodispersed by chemically reducing M-ferrite nanoparticles, which are obtained by means of wet synthesis, in hydrogen and utilizing phase separation by means of a disproportionation reaction while simultaneously carrying out grain growth. Furthermore, a solid magnetic material is obtained by sintering this powder.

A method for producing a magnetic powder includes the steps of: mixing neodymium oxide, boron, and iron to prepare a first mixture; adding and mixing calcium to the first mixture to prepare a second mixture; mixing an alkali metal with the second mixture to prepare a third mixture; and placing a carbon sheet on the third mixture, placing silica sand (SiO.sub.2 sand) thereon, and then heating the same to a temperature of 800 C. to 1100 C.

Provided is a forming method of a metal layer suitable for a 3D printing process. The method includes the steps of providing a plurality of metal particles on a substrate; applying an oxide-removing agent to the metal particles to remove metal oxides on the metal particles; at a first temperature, performing a first heat treatment on the metal particles for which the metal oxides are removed to form a near shape; and at a second temperature, performing a second heat treatment on the near shape to form a sintered body. The first temperature is lower than the second temperature.

Provided is a forming method of a metal layer suitable for a 3D printing process. The method includes the steps of providing a plurality of metal particles on a substrate; applying an oxide-removing agent to the metal particles to remove metal oxides on the metal particles; at a first temperature, performing a first heat treatment on the metal particles for which the metal oxides are removed to form a near shape; and at a second temperature, performing a second heat treatment on the near shape to form a sintered body. The first temperature is lower than the second temperature.

A raw material for a magnet, which comprises Sm and Fe. A magnet is obtained by nitriding this raw material for a magnet. In particular, a raw material for a magnet comprises an SmFe binary alloy as a main component. An intensity ratio of an Sm.sub.2Fe.sub.17 (024) peak to an SmFe.sub.7 (110) peak is less than 0.001 as measured by an X-ray diffraction method.

A raw material for a magnet, which comprises Sm and Fe. A magnet is obtained by nitriding this raw material for a magnet. In particular, a raw material for a magnet comprises an SmFe binary alloy as a main component. An intensity ratio of an Sm.sub.2Fe.sub.17 (024) peak to an SmFe.sub.7 (110) peak is less than 0.001 as measured by an X-ray diffraction method.

A process for producing Co, Al alloyed NdFeB nanoparticles, by a microwave assisted combustion process, followed by a reduction diffusion process, includes the steps of: preparing a first solution of boric acid dissolved in 4 N HNO.sub.3, dissolving iron nitrate nonahydrate, neodymium nitrate hexahydrate, cobalt nitrate hexahydrate, aluminium nitrate, the first solution in deionized water to form a second solution, adding glycine to the second solution in a molar ratio of 1:1 to form a third solution, subjecting the third solution to microwave radiation, thereby forming an first powder of NdFeCoAlB oxides, mixing the first powder with calcium hydride in a mass ratio of 1:1.1 (NdFeCoAlB oxides:CaH.sub.2) to form a second powder, compacted into a powder block, annealing the second powder in a vacuum furnace, washing the annealed second powder with a solution of ethylenediaminetetraacetic acid; and vacuum drying the second powder.