A thin metal strip is produced by a single roll strip casting process, using a cooling roll, a tundish, and a molten metal remover. The cooling roll has an outer peripheral surface, on which it cools and solidifies molten metal while rotating. The tundish can accommodate the molten metal and supplies it onto the outer peripheral surface of the cooling roll. The molten metal remover is disposed downstream of the tundish in the rotating direction of the cooling roll with a gap A between the molten metal remover and an outer peripheral surface of the cooling roll, and removes a surface portion of the molten metal on the outer peripheral surface of the cooling roll to cut down the thickness of the molten metal to the width of the gap A.

The present disclosure is directed to methods of preparing permanent magnets having improved coercivity and remanence, the method comprising: (a) homogenizing a first population of particles of a first GBM alloy with a second population of particles of a second alloy to form a composite alloy preform, the first GBM alloy being represented by the formula: AC.sub.bR.sub.xCo.sub.yCu.sub.dM.sub.z, the second alloy being 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 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. Embodiments include magnets comprising neodymium-iron-boron core alloys, including Nd.sub.2Fe.sub.14B.

The present disclosure is directed to methods of preparing permanent magnets having improved coercivity and remanence, the method comprising: (a) homogenizing a first population of particles of a first GBM alloy with a second population of particles of a second alloy to form a composite alloy preform, the first GBM alloy being represented by the formula: AC.sub.bR.sub.xCo.sub.yCu.sub.dM.sub.z, the second alloy being 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 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. Embodiments include magnets comprising neodymium-iron-boron core alloys, including Nd.sub.2Fe.sub.14B.

A method and system for recovering a high yield of low carbon ferroalloy, e.g., low carbon ferrochrome, from chromite and low carbon ferrochrome produced by the method. A stoichiometric mixture of feed materials including scrap aluminum granules, lime, silica sand, and chromite ore are provided into a plasma arc furnace. The scrap aluminum granules are produced from used aluminum beverage containers. The feed materials are heated, whereupon the aluminum in the aluminum granules produces an exothermic reaction reducing the chromium oxide and iron oxide in the chromite to produce molten low carbon ferrochrome with molten slag floating thereon. The molten low carbon ferrochrome is extracted, solidified and granulated into granules of low carbon ferrochrome. The molten slag is extracted, solidified and granulated into granules of slag.

A method for preparing a multi-element alloy compound is provided. The method includes the following steps: placing materials to be melted in a high-temperature synthesis zone of a vacuum container after being uniformly mixed, and placing materials to be sublimated in a low-temperature evaporation zone of the vacuum container; heating the materials to be melted in the high-temperature synthesis zone to a molten state to form a molten material; heating the materials to be sublimated in the low-temperature evaporation zone to a gaseous state to allow the sublimated gaseous material to react with the molten material. The prepared multi-element alloy compound, a method for preparing ink by adopting the multi-element alloy compound and the prepared multi-element alloy compound ink, as well as a method for preparing a film absorption layer by adopting the multi-element alloy compound ink and the prepared multi-element alloy compound film absorption layer are provided.

A method for preparing a multi-element alloy compound is provided. The method includes the following steps: placing materials to be melted in a high-temperature synthesis zone of a vacuum container after being uniformly mixed, and placing materials to be sublimated in a low-temperature evaporation zone of the vacuum container; heating the materials to be melted in the high-temperature synthesis zone to a molten state to form a molten material; heating the materials to be sublimated in the low-temperature evaporation zone to a gaseous state to allow the sublimated gaseous material to react with the molten material. The prepared multi-element alloy compound, a method for preparing ink by adopting the multi-element alloy compound and the prepared multi-element alloy compound ink, as well as a method for preparing a film absorption layer by adopting the multi-element alloy compound ink and the prepared multi-element alloy compound film absorption layer are provided.

A continuous method of manufacturing permanent magnets and the permanent magnets created thereby. A fine powder is created from a combination of magnetic metals. The powder (a metal alloy) is placed in a non-magnetic container of any desired shape which could be, for example, a tube. The metal alloy and tube are swaged while a magnetic field is applied. Once swaging is complete, the metal alloy and tube are sintered and then cooled. Instead of sintering, a bonding agent can mixed into the powder. Following cooling, the metal alloy is magnetized by placing it between poles of powerful electromagnets with the desired field direction. The process of the invention enables mass-produced, cost-effective PM products, which are more robust, easily assembled into products, and enables new wire-like shapes with arbitrary magnetization direction. The process enables mass production of permanent magnets of any desired cross section, produces permanent magnets continuously that may be cut to any length, and may, in an embodiment, result in directional magnets

A continuous method of manufacturing permanent magnets and the permanent magnets created thereby. A fine powder is created from a combination of magnetic metals. The powder (a metal alloy) is placed in a non-magnetic container of any desired shape which could be, for example, a tube. The metal alloy and tube are swaged while a magnetic field is applied. Once swaging is complete, the metal alloy and tube are sintered and then cooled. Instead of sintering, a bonding agent can mixed into the powder. Following cooling, the metal alloy is magnetized by placing it between poles of powerful electromagnets with the desired field direction. The process of the invention enables mass-produced, cost-effective PM products, which are more robust, easily assembled into products, and enables new wire-like shapes with arbitrary magnetization direction. The process enables mass production of permanent magnets of any desired cross section, produces permanent magnets continuously that may be cut to any length, and may, in an embodiment, result in directional magnets

Embodiments relate to systems and methods for producing magnetic material. The method includes providing a mixture of alloys. The composition of alloy are not particularly limited. The method includes melting the mixture of alloys to arrive at a molten mixture of alloys. The method includes performing a melt-spinning process to rapidly solidify the molten mixture of alloys via a rotatable wheel to arrive at a preliminary metallic ribbon. The preliminary metallic ribbon having an elongated flat body with a bottom side and a top side, the top side opposite to the bottom side. The method includes performing a grain size refinement and uniformity process, the grain size refinement and uniformity process including delivering a first coolant directly to at least a central region of the top side and/or bottom side of the preliminary metallic ribbon to arrive at a final metallic ribbon.

Embodiments relate to systems and methods for producing magnetic material. The method includes providing a mixture of alloys. The composition of alloy are not particularly limited. The method includes melting the mixture of alloys to arrive at a molten mixture of alloys. The method includes performing a melt-spinning process to rapidly solidify the molten mixture of alloys via a rotatable wheel to arrive at a preliminary metallic ribbon. The preliminary metallic ribbon having an elongated flat body with a bottom side and a top side, the top side opposite to the bottom side. The method includes performing a grain size refinement and uniformity process, the grain size refinement and uniformity process including delivering a first coolant directly to at least a central region of the top side and/or bottom side of the preliminary metallic ribbon to arrive at a final metallic ribbon.