The flaky magnetic metal particles of the embodiments include a plurality of flaky magnetic metal particles, each of the flaky magnetic metal particles including a first magnetic particle including a flat surface, at least one first element selected from the group consisting of Fe, Co and Ni, an average ratio between the maximum length and the minimum length in the flat surface being between 1 and 5 inclusive, an average thickness of the first magnetic particles being between 10 nm and 100 m inclusive, an average aspect ratio of the first magnetic particles being between 5 and 10000 inclusive; and a plurality of second magnetic particles disposed on the flat surface, an average number of the second magnetic particles being five or more, an average diameter of the second magnetic particles being between 10 nm and 1 m inclusive.

A method for producing a phosphate-coated SmFeN-based anisotropic magnetic powder, the method includes: a phosphate treatment of adding an inorganic acid to a slurry containing an SmFeN-based anisotropic magnetic powder, water, and a phosphate compound to adjust a pH of the slurry to a range from 1 to 4.5 to form an SmFeN-based anisotropic magnetic powder having a surface on which a phosphate coating is formed; and oxidizing by heat treating the SmFeN-based anisotropic magnetic powder having the surface on which the phosphate coating is formed, in an oxygen-containing atmosphere at a temperature in a range of 200 C. to 330 C., to form the phosphate-coated SmFeN-based anisotropic magnetic powder.

A magnet includes a three-dimensional structure with nanoscale features, where the three-dimensional structure has a near net shape corresponding to a predefined shape.

A high performance permanent magnet is provided. The permanent magnet includes a composition represented by a composition formula: R.sub.pFe.sub.qM.sub.rCu.sub.tCo.sub.100-p-q-r-t, and a metallic structure including cell phases having a Th.sub.2Zn.sub.17 crystal phase and Cu-rich phases having higher Cu concentration than the cell phases. An average diameter of the cell phases is 220 nm or less, and in a numeric value range from a minimum diameter to a maximum diameter of the cell phases, a ratio of a number of cell phases having a diameter in a numeric value range of less than upper 20% from the maximum diameter is 20% or less of all the cell phases.

To provide a rare earth magnet ensuring excellent magnetic anisotropy while reducing the amount of Nd, etc., and a manufacturing method thereof. A rare earth magnet comprising a crystal grain having an overall composition of (R2.sub.(1-x)R1.sub.x).sub.yFe.sub.100-y-w-z-vCo.sub.wB.sub.zTM.sub.v (wherein R2 is at least one of Nd, Pr, Dy and Tb, R1 is an alloy of at least one or two or more of Ce, La, Gd, Y and Sc, TM is at least one of Ga, Al, Cu, Au, Ag, Zn, In and Mn, 0<x<1, y=12 to 20, z=5.6 to 6.5, w=0 to 8, and v=0 to 2), wherein the average grain size of the crystal grain is 1,000 nm or less, the crystal grain consists of a core and an outer shell, the core has a composition of R1 that is richer than R2, and the outer shell has a composition of R2 that is richer than R1.

A YFe ferromagnetic alloy formed by a rapid quenching process, in which a Fe element is not substituted partially or entirely by a structure stabilization element, has high magnetization, but still has a magnetic anisotropy that is too small for practical use. The present invention teaches that Gd is substituted partially for a binary system YFe or a ternary system YFeCo as a main composition, thereby a magnetic anisotropic magnetic field can be increased, and Gd is substituted partially for a quaternary system YSmFeCo, thereby a magnetic anisotropic magnetic field does not vary or is reduced.

A molding device for molding a magnet roll with a profiled cross-section comprises a heating and kneading unit that supplies, to a cylindrical metal mold, a kneaded material obtained by heating and kneading a raw mixture including ferromagnetic particles and thermoplastic resin, an extrusion molding unit that molds the supplied kneaded material by the metal mold, and a magnetic field generating unit disposed at an end portion of the metal mold in a lengthwise direction that generates a magnetic field inside the metal mold, and the metal mold has a profiled C-shaped cross-section at an inlet for the kneaded material and a profiled cross-section at an outlet for the kneaded material more complex than the inlet.

A permanent magnet having a high coercivity, a method for manufacturing such a permanent magnet, and a device using such a permanent magnet are provided. The permanent magnet has a composition represented by a below-shown Formula (1). Formula (1): (R1-xZrx)a(T1-yMy)bBc. In Formula (1); R is at least one element selected from rare earth elements; T is at least one element selected from a group consisting of Fe, Co and Ni; M is at least one element selected from a group consisting of Al, Si, Ti, V, Cr, Mn, Cu, Hf, Nb, Mo, Ta and W; and each of a, b and c indicates atomic %, and x and y indicate ratios of Zr and M, respectively; and they are numbers that satisfy below-shown Expressions, 5a12, b=100(a+c), 0.1c20, 0.01x0.5, and 0.01y0.5.

There is provided a production method and a production device for producing each of the rare earth sintered magnet sintered bodies without carrying a mold in a sintering furnace. The method includes feeding an alloy powder into a mold having side walls divided into two or more sections; filling the alloy powder into the mold to prepare a filled molded-body; orienting the alloy powder in the filled molded-body by applying a magnetic field to the filled molded-body to prepare an oriented filled-molded-body; detaching the side walls of the mold from the oriented filled-molded-body and retrieving the oriented filled-molded-body from the mold; and sintering the retrieved oriented filled-molded-body. The filling step and the orienting step are performed at different locations. A pulsed magnetic field can be applied in the orienting step and inside of the mold can be partitioned into a plurality of cavities by partitions.

The present invention provides a bonded magnet having good heat resistance. The present invention relates to a bonded magnet containing a SmFeN magnetic powder, nylon 12, and a hexafluoroisopropanol-unextractable component. The present invention also relates to a method of preparing a bonded magnet, including: bringing a raw material bonded magnet containing a SmFeN magnetic powder and nylon 12 into contact with an amorphizing agent; and heat-treating the raw material bonded magnet in contact with the amorphizing agent.