Nanocomposite magnetic materials, methods of manufacturing nanocomposite magnetic materials, and magnetic devices and systems using these nanocomposite magnetic materials are described. A nanocomposite magnetic material can be formed using an electro-infiltration process where nanomaterials (synthesized with tailored size, shape, magnetic properties, and surface chemistries) are infiltrated by electroplated magnetic metals after consolidating the nanomaterials into porous microstructures on planar substrates. The nanomaterials may be considered the inclusion phase, and the magnetic metals may be considered the matrix phase of the multi-phase nanocomposite.

A method of processing an anisotropic permanent magnet includes forming anisotropic flakes from a hulk magnet alloy, each of the anisotropic flakes having an easy magnetization direction with respect to a surface of the flake and combining the anisotropic flakes with a binder to form a mixture. The method further includes extruding or rolling the mixture without applying a magnetic field such that the easy magnetization directions of the anisotropic flakes align to form one or more layers having a magnetization direction aligned with the easy magnetization directions of the anisotropic flakes, and producing the anisotropic permanent magnet from the layers having the magnetization direction such that the anisotropic permanent magnet has a magnetization with. a specific orientation.

A method of manufacturing an SmFeN magnet includes a sealing step of filling a metal sheath with a magnet powder including an SmFeN compound as a main component and sealing the metal sheath, a Magnetic field applying step of applying a magnetic field to the magnet powder sealed in the metal sheath, and magnetizing the magnet powder by magnetically orienting the magnet powder and aligning a direction of magnetic orientation in one direction, a preliminary rolling step of preliminarily rolling the magnetically oriented magnet powder sealed in the metal sheath to make the magnetically oriented magnet powder into a green compact, and a pressurizing step of pressurizing the green compact sealed in the metal sheath and densifying the green compact to form a magnet body, wherein in the preliminary rolling step, the preliminary rolling is performed by lightly rolling the magnetically oriented magnet powder sealed in the metal sheath with a pressure smaller than a pressure in the pressurizing step.

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.

According to an embodiment, a composite permanent magnet includes a matrix of magnetically hard phase grains having an average grain size of 10 nm to 50 m; and magnetically soft phase grains embedded within the matrix, and having an average grain size of at least 50 nm, each grain having an elongated shape with an aspect ratio of at least 2:1. According to another embodiment, a composite permanent magnet includes a matrix of magnetically hard phase grains having an average grain size of 10 nm to 50 m; and magnetically soft phase grains embedded within the matrix, and having an average grain width of at least 50 nm, an average grain height of 20 to 500 nm, and an aspect ratio of at least 2:1. According to yet another embodiment, a method of forming a composite permanent magnet is also provided.

The present invention relates to bulk magnetic nanocomposites and methods of making bulk magnetic nanocomposites.

A permanent magnet comprises crystal grains each including a main phase. An average size of the crystal grains is 1.0 m or less, and a degree of orientation of easy magnetization axes of the crystal grains to an easy magnetization axis of the magnet is 15% or more and 90% or less. A recoil magnetic permeability is 1.13 or more, a residual magnetization is 0.8 T or more and less than 1.16 T, and an intrinsic coercive force is 850 kA/m or more.

In one embodiment, 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 method of making a finished NdFeB magnet includes a first step of providing a rare earth magnet powder. Then, a green compact is formed using the rare earth magnet powder. The green compact includes at least one orientation surface, at least one non-orientation surface, and at least one pressing surface. Next, the green compact is cut using a cutting apparatus along the at least one orientation surface, the at least one non-orientation surface, or the at least one pressing surface, under an inert atmosphere to produce a plurality of sliced compacts. Then, the sliced compacts are sintered to produce sintered compacts. The sintered compacts are annealed to produce annealed compacts. The annealed compacts are then machined to obtain finished NdFeB magnets. The step of cutting is performed before the steps of sintering, annealing, and machining. A cutting apparatus for cutting the green compact is also disclosed herein.

To provide a permanent magnet which uses Ce of an abundant resource and has a great magnetic anisotropy in rare earth permanent magnets. To obtain a permanent magnet having a high magnetic anisotropy due to the trivalent Ce state by setting the abundance ratio C3/(C3+C4) in the main phase grains to be 0.1C3/(C3+C4)0.5 where C3 denotes the number of trivalent Ce atoms and C4 denotes the number of tetravalent Ce atoms.