An R-T-B based permanent magnet includes R-T-B based compounds as main-phase crystal grains. R is a rare earth element. T is iron group element(s) essentially including Fe or Fe and Co. B is boron. A two-grain boundary is contained between the two adjacent main-phase crystal grains. An average grain size of the main-phase crystal grains is 0.9 m or more and 2.8 m or less. A thickness of the two-grain boundary is 5 nm or more and 200 nm or less.

An R-T-B based permanent magnet includes R-T-B based compounds as main-phase crystal grains. R is a rare earth element. T is iron group element(s) essentially including Fe or Fe and Co. B is boron. A two-grain boundary is contained between the two adjacent main-phase crystal grains. An average grain size of the main-phase crystal grains is 0.9 m or more and 2.8 m or less. A thickness of the two-grain boundary is 5 nm or more and 200 nm or less.

Provided in one embodiment is a method, comprising: sintering a plurality of nanocrystalline particulates to form a nanocrystalline alloy, wherein at least some of the nanocrystalline particulates may include a non-equilibrium phase comprising a first metal material and a second metal material, and the first metal material may be soluble in the second metal material. The sintered nanocrystalline alloy may comprise a bulk nanocrystalline alloy.

A system for additively manufacturing a composite part is disclosed. The system may include a vat configured to hold a supply of resin, and a build surface disposed inside the vat. The system may also include a print head configured to discharge a matrix-coated continuous reinforcement onto the build surface, and an energy source configured to expose resin on a surface of the matrix-coated continuous reinforcement to a cure energy.

The present disclosure is directed at methods of preparing rare earth-based permanent magnets having improved coercivity and remanence, the method comprising one or more steps comprising: (a) homogenizing a first population of particles of a first GBM alloy with a second population of particles of a second core alloy to form a composite alloy preform, the first GBM alloy being substantially represented by the formula: AC.sub.bR.sub.xCo.sub.yCu.sub.dM.sub.z, the second core alloy being substantially represented by the formula G.sub.2Fe.sub.14B, where AC, R, M, G, b, x, y, and z are defined; (b) heating the composite alloy preform particles to form a population of mixed alloy particles; (c) compressing the mixed alloy particles, under a magnetic field of a suitable strength to align the magnetic particles with a common direction of magnetization and inert atmosphere, to form a green body; (d) sintering the green body; and (e) annealing the sintered body. Particular embodiments include magnets comprising neodymium-iron-boron core alloys, including Nd.sub.2Fe.sub.14B.

The disclosure relates to sintering compositions that can be used in three-dimensional printing or additive manufacturing processes. The sintering compositions generally include one or more metallic iron-containing powders and a minor amount of a boron-containing powder as a sintering aid. Sintered models or products formed from the sintering compositions have substantially improved density and surface roughness values relative to models formed without the boron-containing powder.

The disclosure relates to sintering compositions that can be used in three-dimensional printing or additive manufacturing processes. The sintering compositions generally include one or more metallic iron-containing powders and a minor amount of a boron-containing powder as a sintering aid. Sintered models or products formed from the sintering compositions have substantially improved density and surface roughness values relative to models formed without the boron-containing powder.

Systems and methods for a stabilized evaporable getter for increased handleability is provided. In certain embodiments, a method includes preparing a first getter material, a second getter material, and a metal material. Additionally, the method includes mixing the first getter material, the second getter material, and the metal material into a mixed getter material. Further, the method includes placing the mixed getter material into a getter holder. Also, the heat-treating the getter holder at a temperature below an activation temperature for an exothermic reaction of the mixed getter material but above a melting temperature of the metal material.

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.