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.

The present invention discloses manufacturing methods of a powder for compacting rare earth magnet powder and rare earth magnet that omit jet milling process, which comprises the steps as follows: 1) casting: casting the molten alloy of rare earth magnet raw material by strip casting method to obtain a quenched alloy with average thickness in a range of 0.20.4 mm; 2) hydrogen decrepitation: decrepitating the quenched alloy and a plurality of rigid balls into a rotating hydrogen decrepitation container simultaneously, the quenched alloy is crushed under a hydrogen pressure between 0.011 MPa, cooling the alloy and the balls, then screening the mixture to remove the rigid balls and obtain the powder. As the jet milling process is omitted, the oxygenation during the process of the jet milling may be avoided, therefore the process may be non-oxide, and the mass production of magnet with super high property may be possible.

A permanent magnet material and a method thereof. The permanent magnet material comprises one or more rare earth elements and one or more transition metal elements, wherein the atomic percentage of the one or more rare earth elements is less than or equal to 13%, and the permanent magnet material has a maximum magnetic energy product of greater than or equal to 18 MGOe.

A method of processing an anisotropic permanent magnet includes forming anisotropic flakes from a bulk 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.

Provided are inverse phase allotrope rare earth (IPARE) magnets, methods of forming thereof, and applications of IPARE magnets. Unlike conventional samarium-cobalt magnets, IPARE magnets maintain their hexagonal lattice structures over a range of equiatomic compositions, such as when concentrations of different elements are within 10 atomic % of each other. An IPARE magnet may comprise cobalt, iron, copper, nickel, and samarium and a concentration of cobalt may be between 17-27 atomic %. An IPARE magnet may be substantially free from zirconium and/or titanium. An IPARE magnet may be formed by quenching a molten mixture of its components. The quenching may be performed in a magnetic field. After quenching, the IPARE magnet may be machined. Furthermore, IPARE magnets may be used as a structural element, e.g. in an electric motor.

A permanent magnet material and a method thereof. The permanent magnet material comprises one or more rare earth elements and one or more transition metal elements, wherein the atomic percentage of the one or more rare earth elements is less than or equal to 13%, and the permanent magnet material has a maximum magnetic energy product of greater than or equal to 18 MGOe.

A soft magnetic alloy including a composition having a formula of ((Fe.sub.(1-(+))X1.sub.X2.sub.).sub.(1-(a+b+c+d+e))M.sub.aB.sub.bP.sub.cCr.sub.dCu.sub.e).sub.1-fC.sub.f. X1 is one or more elements selected from a group of Co and Ni. X2 is one or more elements selected from a group of W, Al, Mn, Ag, Zn, Sn, As, Sb, Bi, N, O, and rare earth elements. M is one or more elements selected from a group of Nb, Hf, Zr, Ta, Ti, Mo, and V. 0.020a0.060, 0.020b0.060, 0c0.030, 0d0.050, 0e0.030, 0<f0.040, 0, 0, and 0+0.50 are satisfied.

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 magnet material of an embodiment includes a composition expressed by R.sub.1N.sub.x(Cr.sub.pSi.sub.qM.sub.1-p-q).sub.z, where R represents at least one element selected from Y, La, Ce, Pr, Nd, and Sm, M represents at least one element selected from Fe and Co, x is 0.5x1.5 (atomic ratio), p is 0.005p0.2 (atomic ratio), q is 0.005q0.2 (atomic ratio), and z is 6.0z7.5 (atomic ratio). The magnet material satisfies a condition of I.sub.-Fe/I.sub.2-17-3<0.05, where I.sub.-Fe is a maximum intensity of X-ray diffraction peaks from an -Fe phase and I.sub.2-17-3 is a maximum intensity of X-ray diffraction peaks from an R.sub.2M.sub.17N.sub.3 phase, in an X-ray diffraction profile of the magnet material.

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.