Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, and recycled used powder. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.

A coating tank 1 provided with a net belt passage opening is prepared, a slurry obtained by dispersing a rare-earth-compound powder in a solvent is continuously supplied to the coating tank 1 to cause the coating tank 1 to overflow, and a plurality of sintered magnet bodies 10 are arranged on a net belt conveyor 5, continuously conveyed horizontally thereon, and passed through the slurry in the coating tank 1 via the net belt passage opening, to apply the slurry to the sintered magnet bodies. The slurry is subsequently dried to continuously apply the powder to the plurality of sintered magnet bodies. As a result, the rare-earth-compound powder can be uniformly applied to the surfaces of the sintered magnet bodies, and the application operation can be performed extremely efficiently.

A tantalum-titanium alloy powder that is highly spherical is described. The alloy powder can be useful in additive manufacturing and other uses. Methods to make the alloy powder are further described as well as methods to utilize the alloy powder in additive manufacturing processes. Resulting products and articles using the alloy powder are further described.

A tantalum-titanium alloy powder that is highly spherical is described. The alloy powder can be useful in additive manufacturing and other uses. Methods to make the alloy powder are further described as well as methods to utilize the alloy powder in additive manufacturing processes. Resulting products and articles using the alloy powder are further described.

There is provided a method for manufacturing a rare earth sintered magnet by many times repetitively finely pulverizing a rare earth alloy on a jet mill by supplying high-pressure nitrogen gas to narrow grain size distribution to make an easy alignment in a magnetic field, and by micronizing crystal grains by using a hydrogenation-disproportionation-desorption-recombination (HDDR) process, to improve the coercivity and thermostability of the rare earth sintered magnet.

There is provided a method for manufacturing a rare earth sintered magnet by many times repetitively finely pulverizing a rare earth alloy on a jet mill by supplying high-pressure nitrogen gas to narrow grain size distribution to make an easy alignment in a magnetic field, and by micronizing crystal grains by using a hydrogenation-disproportionation-desorption-recombination (HDDR) process, to improve the coercivity and thermostability of the rare earth sintered magnet.

The present invention provides a rare earth permanent magnet material and manufacturing method thereof. The manufacturing method of the present invention comprises a multi-arc ion plating step and a infiltrating step, wherein multi-arc ion plating process is adopted to deposit a metal containing a heavy rare earth element on a surface of a sintered neodymium-iron-boron magnet which has a thickness of 10 mm or less in at least one direction; and then heat treatment is performed on the sintered neodymium-iron-boron after deposition. The sum of an intrinsic coercive force (H.sub.cj, in unit of kOe) and a maximum magnetic energy product ((BH).sub.max, in unit of MGOe) of the permanent magnet material of the present invention is 66.8 or more. Moreover, the manufacturing method of the present invention has high production efficiency and does not increase harmful substances, and the price of devices is relatively low.

A coating tank 1 provided with a net belt passage opening is prepared, a slurry obtained by dispersing a rare-earth-compound powder in a solvent is continuously supplied to the coating tank 1 to cause the coating tank 1 to overflow, and a plurality of sintered magnet bodies 10 are arranged on a net belt conveyor 5, continuously conveyed horizontally thereon, and passed through the slurry in the coating tank 1 via the net belt passage opening, to apply the slurry to the sintered magnet bodies. The slurry is subsequently dried to continuously apply the powder to the plurality of sintered magnet bodies. As a result, the rare-earth-compound powder can be uniformly applied to the surfaces of the sintered magnet bodies, and the application operation can be performed extremely efficiently.

Provided is an R-T-B based rare earth magnet. R is one or more rare earth elements, T is one or more transition metal elements essentially including Fe or Fe and Co, and B is boron. B content with respect to a total R-T-B based rare earth magnet is 0.80 mass % or more and 0.98 mass % or less. The R-T-B based rare earth magnet includes an R.sub.1T.sub.4B.sub.4 phase.

Provided is an R-T-B based rare earth magnet. R is one or more rare earth elements, T is one or more transition metal elements essentially including Fe or Fe and Co, and B is boron. B content with respect to a total R-T-B based rare earth magnet is 0.80 mass % or more and 0.98 mass % or less. The R-T-B based rare earth magnet includes an R.sub.1T.sub.4B.sub.4 phase.