The present invention provides a magnetic core having insulating properties, and a method for manufacturing the magnetic core. Provided is a magnetic core manufactured by compression molding and subsequent thermal curing of an iron-based soft magnetic powder having a resin coating formed on particle surfaces thereof. The iron-based soft magnetic powder is one in which the particle surfaces have been coated with an inorganic insulator; the resin coating is an uncured resin coating formed by dry blending the powder with a thermosetting resin at a temperature equal to or greater than the softening point of the thermosetting resin and lower than the thermal curing initiation temperature of the resin; the compression molding is carried out by using a mold to produce a compression molded body; and the thermal curing is carried out at a temperature equal to or greater than the thermal curing initiation temperature of the thermosetting resin.

The present invention provides a magnetic core having insulating properties, and a method for manufacturing the magnetic core. Provided is a magnetic core manufactured by compression molding and subsequent thermal curing of an iron-based soft magnetic powder having a resin coating formed on particle surfaces thereof. The iron-based soft magnetic powder is one in which the particle surfaces have been coated with an inorganic insulator; the resin coating is an uncured resin coating formed by dry blending the powder with a thermosetting resin at a temperature equal to or greater than the softening point of the thermosetting resin and lower than the thermal curing initiation temperature of the resin; the compression molding is carried out by using a mold to produce a compression molded body; and the thermal curing is carried out at a temperature equal to or greater than the thermal curing initiation temperature of the thermosetting resin.

A high-performance permanent magnet is provided. The magnet is expressed by a composition formula: R.sub.pFe.sub.qM.sub.rCu.sub.tCo.sub.100-p-q-r-t. The magnet includes a sintered body including: a plurality of crystal grains each having a Th.sub.2Zn.sub.17 crystal phase; and a plurality of grain boundaries between the crystal grains. If an oxide phase of the R element is defined by a continuous region that is disposed in the sintered body and contains the R element and oxygen having a concentration of 85 atomic percent or more, a ratio of the number of the oxide phases in the grain boundaries to the number of the crystal grains is 1.1 or less.

A high-performance permanent magnet is provided. The magnet is expressed by a composition formula: R.sub.pFe.sub.qM.sub.rCu.sub.tCo.sub.100-p-q-r-t. The magnet includes a sintered body including: a plurality of crystal grains each having a Th.sub.2Zn.sub.17 crystal phase; and a plurality of grain boundaries between the crystal grains. If an oxide phase of the R element is defined by a continuous region that is disposed in the sintered body and contains the R element and oxygen having a concentration of 85 atomic percent or more, a ratio of the number of the oxide phases in the grain boundaries to the number of the crystal grains is 1.1 or less.

Provided are a sintered material excellent in both thermal stress and bonding strength; a connection structure comprising the sintered material; a composition for bonding with which the sintered material can be produced; and a method for producing the sintered material. The sintered material comprises a base portion, one or more buffer portions, and one or more filling portions. The buffer portions and the filling portions are dispersed in the base portion. The base portion is a metal sintered body, each buffer portion is formed from at least one of a pore and a material that is not the same as that of the sintered body, and each filling portion is formed from at least one of particles and fibers. The sintered material satisfies A>B, where A is the kurtosis of volume distribution of the base portions in a three-dimensional image of the sintered material, and B is the kurtosis of volume distribution of the base portions in a three-dimensional image of the sintered material from which the filling portions are removed.

A process for producing a high density aluminum alloy part from a green part like those produced by binder jet additive manufacturing is described. The process utilizes a build powder that includes a densification aid mixed with the aluminum alloy powder and gets incorporated into the green part during the printing process. In some cases, a continuous high flow of nitrogen gas and controlled heating of the green part and provides a high density aluminum alloy part exhibiting densities of 95% or greater.

A process for producing a high density aluminum alloy part from a green part like those produced by binder jet additive manufacturing is described. The process utilizes a build powder that includes a densification aid mixed with the aluminum alloy powder and gets incorporated into the green part during the printing process. In some cases, a continuous high flow of nitrogen gas and controlled heating of the green part and provides a high density aluminum alloy part exhibiting densities of 95% or greater.

A three-dimensional printing formulation can include polymeric powder. The polymeric powder can include high aspect ratio composite particles including glass fibers coated with an encapsulating polymer in an amount from about 5 wt % to about 80 wt % based on a total weight of the polymeric powder, and low aspect ratio filler particles in an amount from about 20 wt % to about 95 wt % based on a total weight of the polymeric powder. The high aspect ratio composite particles can have an aspect ratio from about 7:1 to about 30:1 and the low aspect ratio filler particles can have an aspect ratio from 1:1 to less than 7:1.

A three-dimensional printing formulation can include polymeric powder. The polymeric powder can include high aspect ratio composite particles including glass fibers coated with an encapsulating polymer in an amount from about 5 wt % to about 80 wt % based on a total weight of the polymeric powder, and low aspect ratio filler particles in an amount from about 20 wt % to about 95 wt % based on a total weight of the polymeric powder. The high aspect ratio composite particles can have an aspect ratio from about 7:1 to about 30:1 and the low aspect ratio filler particles can have an aspect ratio from 1:1 to less than 7:1.

A composition for binding metal oxides, a metal oxide pellet produced with the binder and metal oxide, and methods for producing the metal oxide pellets. The binder composition includes a pelletizing agent comprising at least one of a cement, a bitumen, and a polymer and a sinter enhancer comprising at least one of a metal sulfide, a metal chloride, and a metal nitrate.