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 raw material for a magnet, which comprises Sm and Fe. A magnet is obtained by nitriding this raw material for a magnet. In particular, a raw material for a magnet comprises an SmFe binary alloy as a main component. An intensity ratio of an Sm.sub.2Fe.sub.17 (024) peak to an SmFe.sub.7 (110) peak is less than 0.001 as measured by an X-ray diffraction method.

A raw material for a magnet, which comprises Sm and Fe. A magnet is obtained by nitriding this raw material for a magnet. In particular, a raw material for a magnet comprises an SmFe binary alloy as a main component. An intensity ratio of an Sm.sub.2Fe.sub.17 (024) peak to an SmFe.sub.7 (110) peak is less than 0.001 as measured by an X-ray diffraction method.

There is provided a production method and a production device for producing each of the rare earth sintered magnet sintered bodies without carrying a mold in a sintering furnace. The method includes feeding an alloy powder into a mold having side walls divided into two or more sections; filling the alloy powder into the mold to prepare a filled molded-body; orienting the alloy powder in the filled molded-body by applying a magnetic field to the filled molded-body to prepare an oriented filled-molded-body; detaching the side walls of the mold from the oriented filled-molded-body and retrieving the oriented filled-molded-body from the mold; and sintering the retrieved oriented filled-molded-body. The filling step and the orienting step are performed at different locations. A pulsed magnetic field can be applied in the orienting step and inside of the mold can be partitioned into a plurality of cavities by partitions.

There is provided a production method and a production device for producing each of the rare earth sintered magnet sintered bodies without carrying a mold in a sintering furnace. The method includes feeding an alloy powder into a mold having side walls divided into two or more sections; filling the alloy powder into the mold to prepare a filled molded-body; orienting the alloy powder in the filled molded-body by applying a magnetic field to the filled molded-body to prepare an oriented filled-molded-body; detaching the side walls of the mold from the oriented filled-molded-body and retrieving the oriented filled-molded-body from the mold; and sintering the retrieved oriented filled-molded-body. The filling step and the orienting step are performed at different locations. A pulsed magnetic field can be applied in the orienting step and inside of the mold can be partitioned into a plurality of cavities by partitions.

Anisotropic rare earth magnet powder particles include R.sub.2TM.sub.14B.sub.1-type crystals of a tetragonal compound consisting of one or more rare earth element, B, and one or more transition element, and enveloping layers containing at least Nd and Cu. Surfaces of the R.sub.2TM.sub.14B.sub.1-type crystals are enveloped by the enveloping layers. The particles has an average crystal grain diameter of 0.05 to 1 m. The particles contain, when the whole particles are taken as 100 atomic %, 11.5 to 15 atomic % of total rare earth element (Rt); 5.5 to 8 atomic % of B; and about 0.05 atomic % to about 2 atomic % of Cu. The powder particles have an atomic ratio of Cu, which is a ratio of the total number of Cu atoms to a total number of atoms of Rt, falling within the range of 1 to 6%. The powder particles do not include dysprosium Dy, Tb, Ho and Ga. Coercivity of the magnetic powder is more than 955 kA/m.

A method for manufacturing a titanium based product includes the following steps. The first step is providing a titanium hydride ingot. The next step is pre-sintering the titanium hydride ingot to dehydrogenate the titanium hydride ingot according to a first temperature control mode, so as to form a titanium ingot. The next step is machining the titanium ingot to form a titanium semi-product having a desired shape. The last step is post-sintering the titanium semi-product according to a second temperature control mode that is different from the first temperature control mode, so as to form the titanium based product.

A method for manufacturing a titanium based product includes the following steps. The first step is providing a titanium hydride ingot. The next step is pre-sintering the titanium hydride ingot to dehydrogenate the titanium hydride ingot according to a first temperature control mode, so as to form a titanium ingot. The next step is machining the titanium ingot to form a titanium semi-product having a desired shape. The last step is post-sintering the titanium semi-product according to a second temperature control mode that is different from the first temperature control mode, so as to form the titanium based product.

An R-T-B based rare earth permanent magnet is expressed by a compositional formula: (R11x(Y1yz Cey Laz)x)aTbBcMd in which R1 is one or more kinds of rare earth element not including Y, Ce and La, T is one or more kinds of transition metal, and includes Fe or Fe and Co as an essential component, M is an element having Ga or Ga and one or more kinds selected from Sn, Bi and Si, and 0.4x0.7, 0.00y+z0.20, 0.16a/b0.28, 0.050c/b0.075 and 0.005d/b0.028. The magnet includes a main phase, including a compound having a R2T14B type tetragonal structure, and a grain boundary phase. D10, D50, D90 of crystal grain diameter according to the main phase crystal grains satisfies the following formula: D504.00 m and (D90D10)/D501.60. A coating rate of the grain boundary is 70.0% or more.

An R-T-B based rare earth permanent magnet is expressed by a compositional formula: (R11x(Y1yz Cey Laz)x)aTbBcMd in which R1 is one or more kinds of rare earth element not including Y, Ce and La, T is one or more kinds of transition metal, and includes Fe or Fe and Co as an essential component, M is an element having Ga or Ga and one or more kinds selected from Sn, Bi and Si, and 0.4x0.7, 0.00y+z0.20, 0.16a/b0.28, 0.050c/b0.075 and 0.005d/b0.028. The magnet includes a main phase, including a compound having a R2T14B type tetragonal structure, and a grain boundary phase. D10, D50, D90 of crystal grain diameter according to the main phase crystal grains satisfies the following formula: D504.00 m and (D90D10)/D501.60. A coating rate of the grain boundary is 70.0% or more.