A sintered Nd—Fe—B magnet comprising at least one light rare earth element having a weight content between 31 wt. % and 35 wt. %, at least one heavy rare earth element having a weight content of no more than 0.2 wt. %, B having a weight content between 0.95 wt. % and 1.2 wt. %, at least one additive including Ti and having a weight content between 1.31 wt. % and 7.2 wt. %, Fe as a balance, and impurities including C, O, and N. Ti has a weight content between 0.3 wt. % and 1 wt. % and forms a Titanium-Iron-Boron phase with Fe and Boron B and being present in the sintered Nd—Fe—B magnet between 0.86 vol. % and 2.85 vol. %. The C, O, and N satisfy 630 ppm≦1.2C+0.6O+N≦3680 ppm. The sintered Nd—Fe—B magnet has a squareness factor of at least 0.95.

A sintered Nd—Fe—B magnet comprising at least one light rare earth element having a weight content between 31 wt. % and 35 wt. %, at least one heavy rare earth element having a weight content of no more than 0.2 wt. %, B having a weight content between 0.95 wt. % and 1.2 wt. %, at least one additive including Ti and having a weight content between 1.31 wt. % and 7.2 wt. %, Fe as a balance, and impurities including C, O, and N. Ti has a weight content between 0.3 wt. % and 1 wt. % and forms a Titanium-Iron-Boron phase with Fe and Boron B and being present in the sintered Nd—Fe—B magnet between 0.86 vol. % and 2.85 vol. %. The C, O, and N satisfy 630 ppm≦1.2C+0.6O+N≦3680 ppm. The sintered Nd—Fe—B magnet has a squareness factor of at least 0.95.

A process for making full dense components of a carbon-containing steel, comprises the steps of: a) making a powder of the carbon-containing steel by gas atomization wherein the carbon content is low, less than 0.15 wt %, b) agglomerating the powder from step a) with at least one hydrocolloid and elemental carbon, c) compacting the agglomerated powder from step b) to a density of at least 80% of theoretical density, with the proviso that the compacted agglomerated powder still is porous allowing transport of gas to and from its interior, and d) sintering the compacted powder to a density of more than 98% of theoretical density, preferably more than 99% of theoretical density, wherein a gas comprising carbon is added during sintering and finally subjecting the component to HVC. Advantages include that it is possible to manufacture a dense component of powders which otherwise are difficult to compact.

A process for making full dense components of a carbon-containing steel, comprises the steps of: a) making a powder of the carbon-containing steel by gas atomization wherein the carbon content is low, less than 0.15 wt %, b) agglomerating the powder from step a) with at least one hydrocolloid and elemental carbon, c) compacting the agglomerated powder from step b) to a density of at least 80% of theoretical density, with the proviso that the compacted agglomerated powder still is porous allowing transport of gas to and from its interior, and d) sintering the compacted powder to a density of more than 98% of theoretical density, preferably more than 99% of theoretical density, wherein a gas comprising carbon is added during sintering and finally subjecting the component to HVC. Advantages include that it is possible to manufacture a dense component of powders which otherwise are difficult to compact.

A mold which is inexpensive and easy to process and does not embrittle. Also provided is a process by which a sintered NdFeB magnet can be produced using the mold without suffering bending or deformation. At least part (e.g., a bottom plate) of the mold is made of a carbon material. Carbon materials have lower friction with a sinter during sintering than metals. The mold hence enables a sintered NdFeB magnet to be produced without suffering the bending or deformation caused by friction due to sintering shrinkage. Carbon materials are inexpensive and easy to process. The mold does not embrittle even when repeatedly used. Such effects can be significantly produced when a carbon material is used as the bottom plate, on which the load of the sinter is imposed during sintering.

A mold which is inexpensive and easy to process and does not embrittle. Also provided is a process by which a sintered NdFeB magnet can be produced using the mold without suffering bending or deformation. At least part (e.g., a bottom plate) of the mold is made of a carbon material. Carbon materials have lower friction with a sinter during sintering than metals. The mold hence enables a sintered NdFeB magnet to be produced without suffering the bending or deformation caused by friction due to sintering shrinkage. Carbon materials are inexpensive and easy to process. The mold does not embrittle even when repeatedly used. Such effects can be significantly produced when a carbon material is used as the bottom plate, on which the load of the sinter is imposed during sintering.

A mold which is inexpensive and easy to process and does not embrittle. Also provided is a process by which a sintered NdFeB magnet can be produced using the mold without suffering bending or deformation. At least part (e.g., a bottom plate) of the mold is made of a carbon material. Carbon materials have lower friction with a sinter during sintering than metals. The mold hence enables a sintered NdFeB magnet to be produced without suffering the bending or deformation caused by friction due to sintering shrinkage. Carbon materials are inexpensive and easy to process. The mold does not embrittle even when repeatedly used. Such effects can be significantly produced when a carbon material is used as the bottom plate, on which the load of the sinter is imposed during sintering.

Systems and methods of synthesizing nanoparticles on substrates using rapid, high temperature thermal shock. A method involves depositing micro-sized particles or salt precursors on a substrate, and applying a rapid, high temperature thermal pulse or shock to the micro-sized particles or the salt precursors and the substrate to cause the micro-sized particles or the salt precursors to become nanoparticles on the substrate. A system may include a rotatable member that receives a roll of a substrate sheet having micro-sized particles or salt precursors; a motor that rotates the rotatable member so as to unroll consecutive portions of the substrate sheet from the roll; and a thermal energy source that applies a short, high temperature thermal shock to consecutive portions of the substrate sheet that are unrolled from the roll by rotating the first rotatable member. Some systems and methods produce nanoparticles on existing substrate. The nanoparticles may be metallic, ceramic, inorganic, semiconductor, or compound nanoparticles. The substrate may be a carbon-based substrate, a conducting substrate, or a non-conducting substrate. The high temperature thermal shock process may be enabled by electrical Joule heating, microwave heating, thermal radiative heating, plasma heating, or laser heating.

Systems and methods of synthesizing nanoparticles on substrates using rapid, high temperature thermal shock. A method involves depositing micro-sized particles or salt precursors on a substrate, and applying a rapid, high temperature thermal pulse or shock to the micro-sized particles or the salt precursors and the substrate to cause the micro-sized particles or the salt precursors to become nanoparticles on the substrate. A system may include a rotatable member that receives a roll of a substrate sheet having micro-sized particles or salt precursors; a motor that rotates the rotatable member so as to unroll consecutive portions of the substrate sheet from the roll; and a thermal energy source that applies a short, high temperature thermal shock to consecutive portions of the substrate sheet that are unrolled from the roll by rotating the first rotatable member. Some systems and methods produce nanoparticles on existing substrate. The nanoparticles may be metallic, ceramic, inorganic, semiconductor, or compound nanoparticles. The substrate may be a carbon-based substrate, a conducting substrate, or a non-conducting substrate. The high temperature thermal shock process may be enabled by electrical Joule heating, microwave heating, thermal radiative heating, plasma heating, or laser heating.

A method for the manufacture of a metal part, the method including the steps: a) compacting agglomerated spherical metal powder to a preform, b) debinding and sintering the preform to a part at a temperature not exceeding 1275° C., c) performing one of the following steps: i) compacting the part to a density of more than 95% of the theoretical density, or ii) compacting the part to a density of less than 95% of the theoretical density and sintering the part at a temperature not exceeding 1275° C. to a density of more than 95% of the theoretical density, and d) subjecting the part to hot isostatic pressing at a temperature not exceeding 1200° C. The method provides an industrial process to produce fully dense parts from alloys which normally cannot be produced and still give good impact properties, which is vital for many applications where there alloys are used.