To provide a rare earth magnet having excellent coercive force and a production method thereof. A rare earth magnet, wherein the rare earth magnet comprises a magnetic phase containing Sm, Fe, and N, a Zn phase present around the magnetic phase, and an intermediate phase present between the magnetic phase and the Zn phase, wherein the intermediate phase contains Zn and the oxygen content of the intermediate phase is higher than the oxygen content of the Zn phase; and a method for producing a rare earth magnet, including mixing a magnetic raw material powder having an oxygen content of 1.0 mass % or less and an improving agent powder containing metallic Zn and/or a Zn alloy, and heat-treating the mixed powder.

Provided is a plurality of flaky magnetic metal particles of embodiments, each flaky magnetic metal particle having a flat surface having either or both of a plurality of concavities and a plurality of convexities, the concavities or convexities being arranged in a first direction and each having a width of 0.1 μm or more, a length of 1 μm or more, and an aspect ratio of 2 or higher; and a magnetic metal phase containing at least one primary element selected from the group consisting of iron (Fe), cobalt (Co), and nickel (Ni). The flaky magnetic metal particles have an average thickness of between 10 nm and 100 μm inclusive, and the average value of the ratio of the average length within the flat surface with respect to the thickness is between 5 and 10,000 inclusive.

Provided is a plurality of flaky magnetic metal particles of embodiments, each flaky magnetic metal particle having a flat surface having either or both of a plurality of concavities and a plurality of convexities, the concavities or convexities being arranged in a first direction and each having a width of 0.1 μm or more, a length of 1 μm or more, and an aspect ratio of 2 or higher; and a magnetic metal phase containing at least one primary element selected from the group consisting of iron (Fe), cobalt (Co), and nickel (Ni). The flaky magnetic metal particles have an average thickness of between 10 nm and 100 μm inclusive, and the average value of the ratio of the average length within the flat surface with respect to the thickness is between 5 and 10,000 inclusive.

Provided is a permanent magnet including a rare-earth element R, a transition metal element T, B, Zr, and Cu. The permanent magnet contains main phase grains including Nd, T, and B, and grain boundary multiple junctions, the grain boundary multiple junction is a grain boundary surrounded by three or more of the main phase grains, one of the grain boundary multiple junctions contains a ZrB.sub.2 crystal and an R—Cu-rich phase, a concentration of B in the grain boundary multiple junction containing both the ZrB.sub.2 crystal and the R—Cu-rich phase is from 5 to 20 atomic %, a concentration of Cu in the grain boundary multiple junction containing both the ZrB.sub.2 crystal and the R—Cu-rich phase is from 5 to 25 atomic %, and a surface layer part of the main phase grain includes at least one kind of heavy rare-earth element among Tb and Dy.

Provided is a permanent magnet including a rare-earth element R, a transition metal element T, B, Zr, and Cu. The permanent magnet contains main phase grains including Nd, T, and B, and grain boundary multiple junctions, the grain boundary multiple junction is a grain boundary surrounded by three or more of the main phase grains, one of the grain boundary multiple junctions contains a ZrB.sub.2 crystal and an R—Cu-rich phase, a concentration of B in the grain boundary multiple junction containing both the ZrB.sub.2 crystal and the R—Cu-rich phase is from 5 to 20 atomic %, a concentration of Cu in the grain boundary multiple junction containing both the ZrB.sub.2 crystal and the R—Cu-rich phase is from 5 to 25 atomic %, and a surface layer part of the main phase grain includes at least one kind of heavy rare-earth element among Tb and Dy.

An R-T-B-based permanent magnet which contains R that represents at least one rare earth element essentially including Tb or Dy, T that represents Fe or at least one iron-group element essentially including Fe and Co, and B that represents boron, and further contains Cu. The total content of R is 28.35 to 29.95% by mass, inclusive, the content of Cu is 0.05 to 0.40% by mass, inclusive, and the content of B is 0.93 to 1.00% by mass, inclusive. The distribution of the concentration of Tb or Dy decreases from the outside of the R-T-B-based permanent magnet toward the inside of the R-T-B-based permanent magnet.

A method for continuous manufacture of permanent magnets. A material sheet is formed into an open tube, having a lengthwise opening. Magnetic powder may be poured into the lengthwise opening on a continuous basis. The tube opening is then formed closed and sealed. The magnetic powder is magnetically pre-aligned by subjecting it to a first magnetic field. The tube containing the powder may be compressed into a desired shape, forming an elongated permanent magnet. After compression, the elongated magnet is magnetized by a second magnetic field in two-step process, wherein the elongated permanent magnet is subjected to a magnetic field from first magnetizing coil that is pulsed with a first electric current in a first direction, followed by a second magnetizing coil being pulsed with a second magnetizing electric current in a second direction. The elongated magnet may be formed into any arbitrary shape, such as a ring or coil.

A method for continuous manufacture of permanent magnets. A material sheet is formed into an open tube, having a lengthwise opening. Magnetic powder may be poured into the lengthwise opening on a continuous basis. The tube opening is then formed closed and sealed. The magnetic powder is magnetically pre-aligned by subjecting it to a first magnetic field. The tube containing the powder may be compressed into a desired shape, forming an elongated permanent magnet. After compression, the elongated magnet is magnetized by a second magnetic field in two-step process, wherein the elongated permanent magnet is subjected to a magnetic field from first magnetizing coil that is pulsed with a first electric current in a first direction, followed by a second magnetizing coil being pulsed with a second magnetizing electric current in a second direction. The elongated magnet may be formed into any arbitrary shape, such as a ring or coil.

The present disclosure provides a method for preparing a powder material and an application thereof. The preparation method includes: obtaining an initial alloy ribbon including a matrix phase and a dispersed particle phase by solidifying an alloy melt, and then removing the matrix phase in the initial alloy ribbon while retaining the dispersed particle phase, so as to obtain a powder material composed of original dispersed particle phase. The preparation method of the present disclosure is simple in process and can prepare multiple powder materials of nano-level, sub-micron-level and micro-level. The powder materials have good application prospects in the fields such as catalytic materials, powder metallurgy, composite materials, wave-absorbing materials, sterilization materials, metal injection molding, 3D printing and coating.

The present disclosure provides a method for preparing a powder material and an application thereof. The preparation method includes: obtaining an initial alloy ribbon including a matrix phase and a dispersed particle phase by solidifying an alloy melt, and then removing the matrix phase in the initial alloy ribbon while retaining the dispersed particle phase, so as to obtain a powder material composed of original dispersed particle phase. The preparation method of the present disclosure is simple in process and can prepare multiple powder materials of nano-level, sub-micron-level and micro-level. The powder materials have good application prospects in the fields such as catalytic materials, powder metallurgy, composite materials, wave-absorbing materials, sterilization materials, metal injection molding, 3D printing and coating.