A method and apparatus for surface densification of powder metal annular preforms is described. A forming tool has external helical teeth corresponding to internal helical teeth of the preform. A die correspondingly configured to the external splines of the preform circumferentially surrounds the forming tool. The forming tool, die and lower punch(es) collectively define an aperture dimensioned to receive the preform. Upper punch(es) encase the preform in the aperture. Surface densification of the internal surface of the preform is achieved by movement of the preform axially over the forming tool. External splines of the preform and corresponding die splines direct the preform axially while internal helical teeth and corresponding forming teeth direct the forming tool to rotate as the preform moves. The forming teeth have varying dimensions in the circumferential and radial directions to apply compression and relaxation to densify the surface of the preform helical teeth.

A soft magnetic composite comprising an iron or iron alloy ferromagnetic material coated with an oxide material. An interface between the ferromagnetic material and the layer of oxide contains antiphase domain boundaries. Two processes for producing a soft magnetic composite are also provided. One process includes depositing an oxide layer onto an iron or iron alloy ferromagnetic material by molecular beam epitaxy at a partial oxygen pressure of from 1×10.sup.−5 Torr to 1×10.sup.−7 Torr to form a coated composite. The other process includes milling an iron or iron alloy ferromagnetic material powder and an oxide powder by high-energy milling to form a mixture; compacting the mixture and curing in an inert gas atmosphere at a temperature from 500° C. to 1200° C. to form a soft magnetic composite.

A soft magnetic composite comprising an iron or iron alloy ferromagnetic material coated with an oxide material. An interface between the ferromagnetic material and the layer of oxide contains antiphase domain boundaries. Two processes for producing a soft magnetic composite are also provided. One process includes depositing an oxide layer onto an iron or iron alloy ferromagnetic material by molecular beam epitaxy at a partial oxygen pressure of from 1×10.sup.−5 Torr to 1×10.sup.−7 Torr to form a coated composite. The other process includes milling an iron or iron alloy ferromagnetic material powder and an oxide powder by high-energy milling to form a mixture; compacting the mixture and curing in an inert gas atmosphere at a temperature from 500° C. to 1200° C. to form a soft magnetic composite.

A soft magnetic composite comprising an iron or iron alloy ferromagnetic material coated with an oxide material. An interface between the ferromagnetic material and the layer of oxide contains antiphase domain boundaries. Two processes for producing a soft magnetic composite are also provided. One process includes depositing an oxide layer onto an iron or iron alloy ferromagnetic material by molecular beam epitaxy at a partial oxygen pressure of from 1×10.sup.−5 Torr to 1×10.sup.−7 Torr to form a coated composite. The other process includes milling an iron or iron alloy ferromagnetic material powder and an oxide powder by high-energy milling to form a mixture; compacting the mixture and curing in an inert gas atmosphere at a temperature from 500° C. to 1200° C. to form a soft magnetic composite.

A method for fabrication of a composite component including a first material containing steel 316L and a second material containing zirconia powder formed in a single sintering. The method for fabrication includes: a) forming a first injection molding composition including steel 316L powder and a second injection molding composition including zirconia powder; b) agglomerating via injection molding one of the first and second compositions to form at least a first part of a blank; c) agglomerating by injection molding the other of the first and second materials against the first part of the blank to form at least a second part of the blank; and d) non-consecutively sintering the first and second compositions forming the blank to obtain the composite component formed of steel 316L and zirconia.

A method for fabrication of a composite component including a first material containing steel 316L and a second material containing zirconia powder formed in a single sintering. The method for fabrication includes: a) forming a first injection molding composition including steel 316L powder and a second injection molding composition including zirconia powder; b) agglomerating via injection molding one of the first and second compositions to form at least a first part of a blank; c) agglomerating by injection molding the other of the first and second materials against the first part of the blank to form at least a second part of the blank; and d) non-consecutively sintering the first and second compositions forming the blank to obtain the composite component formed of steel 316L and zirconia.

A method of manufacturing a component includes making a preform from a powdered material, the preform having a density in a range from 70 to 95% of theoretical density of the material, The method also includes sintering the preform using a Field Assisted Sintering Technique (FAST) process to produce a component having a density of greater than 97% of the theoretical density of the material. Components, in particular low aspect components, formed by said method are also described.

A neodymium-iron-boron permanent magnet, a preparation method and use thereof are disclosed. The neodymium-iron-boron permanent magnet has a composition represented by formula I: [mHR(1−m) (Pr.sub.25Nd.sub.75)].sub.x(Fe.sub.100-a-b-c-dM.sub.aGa.sub.bIn.sub.cSn.sub.d).sub.100-x-yB.sub.y formula I; where a is 0.995-3.493, b is 0.114-0.375, c is 0.028-0.125, d is 0.022-0.100; x is 29.05-30.94, y is 0.866-1.000; m is 0.02-0.05; HR is Dy and/or Tb; M is at least one selected from the group consisting of Co, Cu, Ti, Al, Nb, Zr, Ni, W and Mo.

A neodymium-iron-boron permanent magnet, a preparation method and use thereof are disclosed. The neodymium-iron-boron permanent magnet has a composition represented by formula I: [mHR(1−m) (Pr.sub.25Nd.sub.75)].sub.x(Fe.sub.100-a-b-c-dM.sub.aGa.sub.bIn.sub.cSn.sub.d).sub.100-x-yB.sub.y formula I; where a is 0.995-3.493, b is 0.114-0.375, c is 0.028-0.125, d is 0.022-0.100; x is 29.05-30.94, y is 0.866-1.000; m is 0.02-0.05; HR is Dy and/or Tb; M is at least one selected from the group consisting of Co, Cu, Ti, Al, Nb, Zr, Ni, W and Mo.

A method for connecting a first component to a second component to form an assembly forms a press fit connection between the first component and the second component, for which purpose the second component is produced having an annular component section. A recess is formed, in which the first component is at least partially arranged. At least the annular component section of the second component is produced as a sintered component and has net shape or near net shape quality at least in the region of the recess.