The present invention relates to a composite component including a metal component having a substantially cylindrical shape or a substantially annular shape, and a ring-shaped bonded magnet disposed on the outer periphery of the metal component, the ring-shaped bonded magnet containing a thermoplastic resin, magnetic particles, and rubber particles.

A process for producing R-T-B-based rare earth magnet powder having excellent coercive force and high remanent flux density. A process for producing R-T-B-based rare earth magnet powder by HDDR treatment, in which a raw material alloy for the R-T-B-based rare earth magnet powder includes R (wherein R represents at least one rare earth element including Y), T (wherein T represents Fe, or Fe and Co) and B (wherein B represents boron), and has a composition including R in an amount of between 12.0 atom % and 17.0 atom %, and B in an amount of between 4.5 atom % and 7.5 atom %; the HDDR treatment includes a DR step including a preliminary evacuation step and a complete evacuation step; and a rate of pressure reduction caused by evacuation in the preliminary evacuation step is not less than 1 kPa/min and not more than 30 kPa/min.

A high-performance permanent magnet is provided. A permanent magnet expressed by a composition formula: R.sub.pFe.sub.qM.sub.rCu.sub.tCo.sub.100-p-q-r-t-. The magnet comprises a metal structure including a cell phase having a Th.sub.2Zn.sub.17 crystal phase, and a Cu-rich phase provided to divide the cell phase and having a Cu concentration higher than that of the Th.sub.2Zn.sub.17 crystal phase. An Fe concentration of the Th.sub.2Zn.sub.17 crystal phase is not less than 30 atomic % nor more than 45 atomic %. An average length of the Cu-rich phase is not less than 30 nm nor more than 250 nm.

A high-performance permanent magnet is provided. A permanent magnet expressed by a composition formula: R.sub.pFe.sub.qM.sub.rCu.sub.tCo.sub.100-p-q-r-t-. The magnet comprises a metal structure including a cell phase having a Th.sub.2Zn.sub.17 crystal phase, and a Cu-rich phase provided to divide the cell phase and having a Cu concentration higher than that of the Th.sub.2Zn.sub.17 crystal phase. An Fe concentration of the Th.sub.2Zn.sub.17 crystal phase is not less than 30 atomic % nor more than 45 atomic %. An average length of the Cu-rich phase is not less than 30 nm nor more than 250 nm.

A rare earth permanent magnet is prepared by immersing a portion of a sintered magnet body of R.sup.1—Fe—B composition (wherein R.sup.1 is a rare earth element) in an electrodepositing bath of a powder dispersed in a solvent, the powder comprising an oxide, fluoride, oxyfluoride, hydride or rare earth alloy of a rare earth element, effecting electrodeposition for letting the powder deposit on a region of the surface of the magnet body, and heat treating the magnet body with the powder deposited thereon at a temperature below the sintering temperature in vacuum or in an inert gas.

A rare earth permanent magnet is prepared by immersing a portion of a sintered magnet body of R.sup.1—Fe—B composition (wherein R.sup.1 is a rare earth element) in an electrodepositing bath of a powder dispersed in a solvent, the powder comprising an oxide, fluoride, oxyfluoride, hydride or rare earth alloy of a rare earth element, effecting electrodeposition for letting the powder deposit on a region of the surface of the magnet body, and heat treating the magnet body with the powder deposited thereon at a temperature below the sintering temperature in vacuum or in an inert gas.

This sintered R-T-B based rare-earth magnet includes: R.sub.2Fe.sub.14B type compound crystal grains, including a light rare-earth element RL (which includes at least one of Nd and Pr) as a major rare-earth element R, as main phases; and a heavy rare-earth element RH (which includes at least one of Dy and Tb). Before its surface region is removed, the sintered R-T-B based rare-earth magnet has no layer including the rare-earth element R at a high concentration in that surface region. The sintered R-T-B based rare-earth magnet has a portion in which coercivity decreases gradually from its surface region toward its core portion. The difference in the amount of TRE between a portion of the sintered R-T-B based rare-earth magnet that reaches a depth of 500 μm as measured from its surface region toward its core portion and the core portion of the sintered R-T-B based rare-earth magnet is 0.1 through 1.0.

A method for producing a NdFeB system sintered magnet. The method includes: a hydrogen pulverization process, in which coarse powder of a NdFeB system alloy is prepared by coarsely pulverizing a lump of NdFeB system alloy by making this lump occlude hydrogen; a fine pulverization process, in which fine powder is prepared by performing fine pulverization for further pulverizing the coarse powder; a filling process, in which the fine powder is put into a filling container; an orienting process, in which the fine powder in the filling container is oriented; and a sintering process, in which the fine powder after the orienting process is sintered as held in the filling container. The processes from hydrogen pulverization through orienting are performed with neither dehydrogenation heating nor evacuation each for desorbing hydrogen occluded in the hydrogen pulverization process. The processes from hydrogen pulverization through sintering are performed in an oxygen-free atmosphere.

Permanent magnets and methods of making the same are disclosed herein. The permanent magnets include a 3D-printed, i.e., additively manufactured, framework and an infiltrate such that there is a discrete magnetic phase and a discrete non-magnetic phase or two discrete magnetic phases. The infiltrate may provide superior strength, elasticity or magnetic properties.

Permanent magnets and methods of making the same are disclosed herein. The permanent magnets include a 3D-printed, i.e., additively manufactured, framework and an infiltrate such that there is a discrete magnetic phase and a discrete non-magnetic phase or two discrete magnetic phases. The infiltrate may provide superior strength, elasticity or magnetic properties.