Methods for the production of magnetic powders, compacted magnetic bodies and sintered magnetic bodies. The methods include the use of metal carboxylate precursor compounds such as metal oxalates. The precursor compounds are heated under pressure to form metal alloy particles which can be directly formed into compacted magnetic bodies or can be further refined by using a reductant at elevated temperatures and pressures. The sintered magnetic bodies may have strong magnetic properties even if produced in the absence of a strong magnetic field.

A method for manufacturing a magnet from recycled magnets comprising the following steps of: providing: a 1st powder comprising grains of a magnetic phase TR.sub.2Fe.sub.14B, metal-based compounds and a grain boundary phase rich in rare earth, said 1st powder being free of heavy rare earth, a 2nd powder obtained from recycled magnets comprising heavy rare earths, the 2nd powder is subjected to a hydrogenation-disproportionation treatment, the 1st powder is mixed with the 2nd powder obtained at the end of step b), the mixture obtained at the end of step c) is subjected to a compacting step so as to obtain a compacted part, the compacted part obtained at the end of step d) is subjected to a sintering step so as to obtain a magnet.

An apparatus for assembling a repelling magnet combination, comprising a first and second magnet, a first and second holding magnet, a first holding base with a first holding base first end, and a second holding base with a second holding base first end. The first and second holding magnets are positioned at the first and second holding base first ends, and the first and second magnets are magnetically attached to the first and second holding magnets respectively, with outward faces exhibiting like magnetic polarities. The first and second magnets are brought into contact by moving the first and second holding base first ends into close proximity, whereby the first and second holding magnets exert holding forces on the first and second magnets which overcome a repelling force generated therebetween, allowing a repelling force countering means, such as an adhesive, to bond the magnets together into a repelling magnet combination.

The disclosed technology provides a nanofunctionalized magnetic material feedstock comprising: from 50 wt % to 99.5 wt % of magnetic microparticles having an average microparticle effective diameter from 1 micron to 500 microns; from 0.4 wt % to 40 wt % of one or more rare earth elements; and from 0.1 wt % to 10 wt % of metal-containing inoculant nanoparticles, wherein at least 1 wt % of the inoculant nanoparticles are chemically and/or physically disposed on surfaces of the magnetic microparticles. The nanofunctionalized magnetic material feedstock is processed using high-throughput laser-based additive manufacturing to optimize the architecture of NdFeB or other magnets, generating site-specific, demagnetization-resistant microstructures. This disclosure teaches a rapid, single-step laser-based process to tailor the easy axis alignment, grain size, and microstructure of a permanent magnet at corners and edges to resist demagnetization.

A magnetic field generator including: a yoke; and a plurality of main magnetic pole magnets and a plurality of secondary magnetic pole magnets, the main magnetic pole magnets and the secondary magnetic pole magnets comprising a rare earth sintered magnet, having magnetic pole orientations different from each other by substantially 90°, and being alternately arranged in a linear Halbach magnet array without gaps and fixed to the yoke, wherein near contact surfaces of the main magnetic pole magnets and the secondary magnetic pole magnets, a grain boundary diffusion layer is formed in which at least one of Dy or Tb being heavy rare earth elements or a compound of at least one of the Dy or the Tb is diffused into internal grain boundaries from the contact surfaces.

A three-dimensional magnet structure (6) made up of a plurality of individual magnets (4), the magnet structure (6) having a thickness that forms its smallest dimension, the magnet structure (6) incorporating at least one mesh (5a) exhibiting mesh cells each one delimiting a housing (5) for a respective individual magnet (4), each housing (5) having internal dimensions just large enough to allow an individual magnet (4) to be inserted into it, the mesh cells being made from a fibre-reinforced insulating material, characterized in that a space is left between the housing (5) and the individual magnet (4), which space is filled with a fibre-reinforced resin, the magnet structure (6) comprising a non-conducting composite layer coating the individual magnets (4) and the mesh structure (5a).

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.

A permanent magnet may include a Fe.sub.16N.sub.2 phase constitution. In some examples, the permanent magnet may be formed by a technique that includes straining an iron wire or sheet comprising at least one iron crystal in a direction substantially parallel to a <001> crystal axis of the iron crystal; nitridizing the iron wire or sheet to form a nitridized iron wire or sheet; annealing the nitridized iron wire or sheet to form a Fe.sub.16N.sub.2 phase constitution in at least a portion of the nitridized iron wire or sheet; and pressing the nitridized iron wires and sheets to form bulk permanent magnet.

The disclosed technology provides a cladded permanent magnet comprising: a core magnet region containing a core magnetic material; and a magnet cladding containing a shell magnetic material comprising (i) a magnetic compound that is chemically the same as the core magnetic material, (ii) one or more rare earth elements, and (iii) metal-containing inoculant nanoparticles, wherein the magnet cladding is disposed on the core magnet region, wherein the magnet cladding has at least 10% higher ambient-temperature magnetic coercivity compared to the core magnet region. The cladded permanent magnet is made via high-throughput laser-based additive manufacturing to optimize the architecture of NdFeB or other magnets, generating site-specific, demagnetization-resistant microstructures. This disclosure teaches a rapid, single-step laser-based process to tailor the easy axis alignment, grain size, and microstructure of a permanent magnet at corners and edges to resist demagnetization.

The present disclosure is drawn to 3D printing kits, multi-fluid kits for 3D printing, and methods of making 3D printed articles. In one example, a 3D printing kit can include a powder bed material, a fusible fluid, and a magnetic fluid. The powder bed material can include polymer particles. The fusible fluid can include water and a radiation absorber. The fusible fluid can be to selectively apply to the powder bed material. The magnetic fluid can include magnetic particles, and the magnetic fluid can be to selectively apply to the powder bed material.