A system may include a current source; a first metal or alloy component with a first major surface electrically coupled to the current source; a second metal or alloy component with a second major surface electrically coupled in series to the first component and the current source via an external electrical conductor, where the first and second major surfaces are positioned adjacent to each other to define a joint region; a metal or alloy powder disposed in at least a portion of the joint region; and a controller. The controller may be configured to cause the current source to output an alternating current that conducts through the first component and the second component to induce magnetic eddy currents, magnetic hysteresis, or both within at least a portion of the metal or alloy powder disposed in at least the first portion of the joint region.

A bulk permanent magnetic material may include between about 5 volume percent and about 40 volume percent Fe.sub.16N.sub.2 phase domains, a plurality of nonmagnetic atoms or molecules forming domain wall pinning sites, and a balance soft magnetic material, wherein at least some of the soft magnetic material is magnetically coupled to the Fe.sub.16N.sub.2 phase domains via exchange spring coupling. In some examples, a bulk permanent magnetic material may be formed by implanting N+ ions in an iron workpiece using ion implantation to form an iron nitride workpiece, pre-annealing the iron nitride workpiece to attach the iron nitride workpiece to a substrate, and post-annealing the iron nitride workpiece to form Fe.sub.16N.sub.2 phase domains within the iron nitride workpiece.

A permanent magnet may include a Fe16N2 phase in a strained state. In some examples, strain may be preserved within the permanent magnet by a technique that includes etching an iron nitride-containing workpiece including Fe16N2 to introduce texture, straining the workpiece, and annealing the workpiece. In some examples, strain may be preserved within the permanent magnet by a technique that includes applying at a first temperature a layer of material to an iron nitride-containing workpiece including Fe16N2, and bringing the layer of material and the iron nitride-containing workpiece to a second temperature, where the material has a different coefficient of thermal expansion than the iron nitride-containing workpiece. A permanent magnet including an Fe16N2 phase with preserved strain also is disclosed.

The present disclosure is directed to methods of preparing substantially spherical metallic alloyed particles, having micron and sub-micron (i.e., nanometer)-scaled dimensions, and the powders so prepared, as well as articles derived from these powders. In particular embodiments, these metallic alloyed particles, comprising rare earth metals, can be prepared in sizes as small 80 nm in diameter with size variances as low as 2-5%.

A three-dimensional object may be manufactured using a powder bed fusion additive manufacturing technique. A layer of powder feed material may be distributed over a solid substrate and scanned with a high-energy laser beam to locally melt selective regions of the layer and form a pool of molten feed material. The pool of molten feed material may be exposed to gaseous nitrogen, carbon, or boron to respectively dissolve nitride, carbide, or boride ions into the pool of molten feed material to produce a molten nitrogen, carbon, or boron-containing solution. The molten nitrogen, carbon, or boron-containing solution may cool and solidify into a solid layer of fused nitride, carbide, or boride-containing material.

A magnet includes a magnet matrix and a bond coating arranged at a surface of the magnet matrix. The bond coating includes a thermosetting adhesive layer and a thermoplastic adhesive layer. The thermosetting adhesive layer includes a foaming agent. The thermosetting adhesive layer and the thermoplastic adhesive layer are arranged in sequence from the surface of the magnet matrix to outside.

The present invention provides for polycrystalline superconducting permanent magnets which are synthesized of doped superconducting (AE) Fe.sub.2As.sub.2 compounds, where AE denotes an alkaline earth metal, such as Ba, Sr, Mg or Ca. The superconducting permanent magnets of the present invention can be magnetized in their superconducting state by induced currents, resulting in trapped magnetization that scales with the size of the bulk material. The magnitude of the trapped field has been demonstrated to be over 1 T and is predicted to be over 10 T if the technology is scaled, which is much higher than the capabilities of permanent magnets and other superconducting polycrystalline bulks currently known in the art.

A manufacturing method for obtaining an interior permanent magnet-type inner rotor without thermal demagnetization due to shrink fitting to a rotating shaft includes: a shrink fitting step of heating a rotor core having slots and inserting a rotating shaft into a shaft hole to shrinkfit the rotor core; and a filling step of filling the rotor core slots in a residual heat state after the shrink fitting step with a flowable mixture of a binder resin heated to a flowable state and anisotropic magnet particles, in oriented magnetic fields This allows, in similar manufacturing steps, an inner rotor of which the magnetic poles are anisotropic bond magnets formed by solidifying the flowable mixture in the slots and a conventional inner rotor of which the magnetic poles are sintered magnets. This allows both the inner rotors concurrently and in parallel (mixed flow production) in an already existing IPM motor manufacturing line.

A permanent magnet formed by additively manufacturing magnetic phases and buffer phases is disclosed. The buffer phase(s) may improve performance, enhance mechanical properties and allow the magnet to better tolerate stresses such that defects such as cracking do not occur or are less likely to occur. The buffer phase may be a magnetic or non-magnetic material.

A magnet array is disclosed comprising a plurality of polyhedral magnets arranged in a Halbach cylinder configuration, the centers of individual ones of the plurality of polyhedral magnets being arranged substantially in a plane in a magnet rack, the plurality of the polyhedral magnets at least partly enclosing a testing volume, and comprising a first plurality of polyhedral magnets arranged in a Halbach cylinder configuration and a second plurality of polyhedral magnets arranged in a non-Halbach configuration. In another aspect, a magnet array is disclosed comprising a first subset and a second subset of polyhedral magnets having different coercivities. In yet another aspect, a magnet array is disclosed wherein a subset of the centers of the individual ones of the plurality of polyhedral magnets are laterally displaced from a nominal position in the magnet rack to counteract a magnetic field gradient of the magnet array.