A manufacturing method of an amorphous soft magnetic core using a Fe-based amorphous metallic powder includes size-sorting an amorphous metallic powder obtained by pulverizing an amorphous ribbon prepared by a rapid solidification process (RSP) and then using the amorphous metallic powder having a particle size distribution so as to comprise 10 to 85 wt. % of powder having a particle size of 75 to 100 m, 10 to 70 wt. % of powder having a particle size of 50 to 75 m, and 5 to 20 wt. % of powder having a particle size of 5 to 50 m to manufacture an amorphous soft magnetic core with excellent high-current DC bias characteristic and good core loss characteristic.

There is provided a thermoelectric conversion material made of a full-Heusler alloy and capable of enhancing figure of merit. In order to solve the above problem, the thermoelectric conversion material is made of the full-Heusler alloy represented by the following composition formula: (Fe.sub.1-xM1.sub.x).sub.2+(Ti.sub.1-yM2.sub.y).sub.1+(A.sub.1-zM3.sub.z).sub.1+. A composition in a ternary phase diagram of FeTi-A is inside a hexagon having points (50, 37, 13), (45, 30, 25), (39.5, 25, 35.5), (50, 14, 36), (54, 21, 25), and (55.5, 25, 19.5) as apexes. Further, an amount of change VEC of an average valence electron number per atom VEC in the case of x=y=z=0 satisfies a relation 0<|VEC|0.2 or 0.2<|VEC|0.3.

There is provided a thermoelectric conversion material made of a full-Heusler alloy and capable of enhancing figure of merit. In order to solve the above problem, the thermoelectric conversion material is made of the full-Heusler alloy represented by the following composition formula: (Fe.sub.1-xM1.sub.x).sub.2+(Ti.sub.1-yM2.sub.y).sub.1+(A.sub.1-zM3.sub.z).sub.1+. A composition in a ternary phase diagram of FeTi-A is inside a hexagon having points (50, 37, 13), (45, 30, 25), (39.5, 25, 35.5), (50, 14, 36), (54, 21, 25), and (55.5, 25, 19.5) as apexes. Further, an amount of change VEC of an average valence electron number per atom VEC in the case of x=y=z=0 satisfies a relation 0<|VEC|0.2 or 0.2<|VEC|0.3.

The present invention provides an undercooling solidification method for preparing an amorphous or nanocrystalline soft magnetic alloy with high Fe content and the applicable amorphous or nanocrystalline alloy composition. The undercooling solidification is realized by glass purification combined with cyclical superheating or electromagnetic levitation melting. An undercooling solidification alloy is prepared into amorphous strips or powders through rapid quenching or atomization of melt, and can be prepared into a nanocrystalline alloy through heat treatment. The chemical formula of the applicable amorphous or nanocrystalline alloy is FeSiBM, wherein M is one or more of P, C, Nb, Mo, Zr, Hf, Mo, Y, Cu and Co. The amorphous or nanocrystalline alloy prepared by undercooling non-equilibrium solidification has the characteristics of high amorphous forming ability, high saturation magnetization and low coercive force.

A permanent magnet contains a rare-earth element R, a transition metal element T, and boron. The permanent magnet contains a plurality of main phase grains and a plurality of soft magnetic grains. The plurality of soft magnetic grains contain Fe. A cross-section of the permanent magnet includes a plurality of soft magnetic regions. The cross-section of the permanent magnet is parallel to an easy magnetization axis direction of the permanent magnet. Each of the plurality of soft magnetic regions contains the plurality of soft magnetic grains aligned along a direction orthogonal to the easy magnetization axis direction. The plurality of main phase grains and the plurality of soft magnetic regions are alternately disposed in the easy magnetization axis direction. An average value of width of the plurality of soft magnetic grains in the easy magnetization axis direction ranges from 20 nm to 5 ?m.

Provided are an auxiliary alloy casting piece, a high-remanence and high-coercive force NdFeB permanent magnet, and preparation methods thereof. The method for preparing the auxiliary alloy casting piece includes the following steps: providing an auxiliary alloy material including, by mass percentage, 40% to 45% of Pr, 1% to 2% of Co, 0.5% to 1% of Ga, 0.6% to 0.8% of B, 0.1% to 0.2% of V, 0.3% to 0.7% of Ti, and a balance of Fe; smelting the auxiliary alloy material to obtain a smelted material; and subjecting the smelted material to a quick-setting casting to obtain the auxiliary alloy casting piece; where the quick-setting casting includes a refining and a casting in sequence.

Provided are an auxiliary alloy casting piece, a high-remanence and high-coercive force NdFeB permanent magnet, and preparation methods thereof. The method for preparing the auxiliary alloy casting piece includes the following steps: providing an auxiliary alloy material including, by mass percentage, 40% to 45% of Pr, 1% to 2% of Co, 0.5% to 1% of Ga, 0.6% to 0.8% of B, 0.1% to 0.2% of V, 0.3% to 0.7% of Ti, and a balance of Fe; smelting the auxiliary alloy material to obtain a smelted material; and subjecting the smelted material to a quick-setting casting to obtain the auxiliary alloy casting piece; where the quick-setting casting includes a refining and a casting in sequence.

A magnetic powder contains at least the first alloy powder and the second alloy powder in which those composition are different. The second alloy powder has a smaller median diameter than the first alloy powder and contains Cr of 0.3-14 at %. The first alloy powder has a Cr content of 0.3 at % or less. With respect to the total sum of the first alloy powder and the second alloy powder, a content of the second alloy powder is 20-50 vol % and the ratio of the median diameter of the first alloy powder to the second alloy powder is 4-20. The first alloy powder comprises either an amorphous phase or a crystalline phase having an average crystallite size of 50 nm or smaller. Thereby, a magnetic powder having low magnetic loss and good corrosion resistance without damaging insulation resistance and saturation magnetic flux density can be realized.

A magnetic powder contains at least the first alloy powder and the second alloy powder in which those composition are different. The second alloy powder has a smaller median diameter than the first alloy powder and contains Cr of 0.3-14 at %. The first alloy powder has a Cr content of 0.3 at % or less. With respect to the total sum of the first alloy powder and the second alloy powder, a content of the second alloy powder is 20-50 vol % and the ratio of the median diameter of the first alloy powder to the second alloy powder is 4-20. The first alloy powder comprises either an amorphous phase or a crystalline phase having an average crystallite size of 50 nm or smaller. Thereby, a magnetic powder having low magnetic loss and good corrosion resistance without damaging insulation resistance and saturation magnetic flux density can be realized.

The present invention relates to an SmFeN magnet material including: 7.0-12 at % of Sm; 0.1-1.5 at % of at least one element selected from the group consisting of Hf, Zr, and Sc; 0.1-0.5 at % of Mn; 10-20 at % of N; and 0-35 at % of Co, with the remainder being Fe and unavoidable impurities. The present invention also relates to an SmFeN bonded magnet including a powder of the SmFeN magnet material and a binder.