A method includes depositing a layer of alloy particles including rare earth permanent magnet phase above a substrate, laser scanning the layer while cooling the substrate to melt the particles, selectively initiate crystal nucleation, and promote columnar grain growth in a same direction as an easy axis of the rare earth permanent magnet phase. The method also includes repeating the depositing and scanning to form bulk anisotropic rare earth alloy magnet with aligned columnar grains.

A sintered R-T-B based magnet work contains R: 27.5 to 35.0 mass % (R is at least one rare-earth element which always includes Nd), B: 0.80 to 0.99 mass %, Ga: 0 to 0.8 mass %, M: 0 to 2 mass % (M is at least one of Cu, Al, Nb and Zr), and a balance T (T is at least one transition metal element which always includes Fe, with 10% or less of Fe replaceable by Co). [T]/55.85>14[B]/10.8 is satisfied where [T] is the T content (mass %) and [B] is the B content (mass %). At least a portion of a Pr—Ga alloy is in contact with a portion of the sintered magnet work surface, and a first heat treatment is performed at a temperature between 600° C. and 950° C. A second heat treatment is performed at a temperature lower than the temperature of the first heat treatment and between 450° C. and 750° C.

The present invention provides a method for manufacturing a rare-earth magnet, the method comprising the steps of preparing a rare-earth magnet raw material powder including R, Fe and B as composition components (R is one or more elements selected from the rare earth elements including Y and Sc); packing the raw material powder into a molding die, and compacting and molding the raw material powder while applying a magnetic field, wherein, in the compacting and molding step, compacting is performed biaxially, in the directions of X and Y axes, when the magnetic field is applied in the direction of Z axis.

The present disclosure is directed to methods of preparing substantially spherical metallic alloyed particles, having micron and sub-micron (i.e., nanometer)-scaled dimensions, and the powders so prepared, as well as articles derived from these powders. In particular embodiments, these metallic alloyed particles, comprising rare earth metals, can be prepared in sizes as small 80 nm in diameter with size variances as low as 2-5%.

A sintered magnet body (R.sub.aT.sup.1.sub.bM.sub.cB.sub.d) coated with a powder mixture of an intermetallic compound (R.sup.1.sub.iM.sup.1.sub.j, R.sup.1.sub.xT.sup.2.sub.yM.sup.1.sub.z, R.sup.1.sub.iM.sup.1.sub.jH.sub.k), alloy (M.sup.1.sub.dM.sup.2.sub.e) or metal (M.sup.1) powder and a rare earth (R.sup.2) oxide is diffusion treated. The R.sup.2 oxide is partially reduced during the diffusion treatment, so a significant amount of R.sup.2 can be introduced near interfaces of primary phase grains within the magnet through the passages in the form of grain boundaries. The coercive force is increased while minimizing a decline of remanence.

The present disclosure relates to an iron-chromium-aluminum (Fe—Cr—Al) powder suitable for additive manufacturing and to an additive manufacturing process. The present disclosure also relates to an additive manufactured object.

An R-T-B based permanent magnet in which R is a rare earth element, T is Fe or a combination of Fe and Co, B is boron, and further includes M. The R-T-B based permanent magnet includes main phase grains consisting of R.sub.2T.sub.14B phase. M at least includes Ga and Zr. The R-T-B based permanent magnet further includes C and O. R content is 29.0 mass % to 33.0 mass %, B content is 0.85 mass % to 1.05 mass %, Ga content is 0.30 mass % to 1.20 mass %, 0 content is 0.03 mass % to 0.20 mass %, and C content is 0.03 mass % to 0.30 mass %. Further, the R-T-B based permanent magnet satisfies 3.48m(B)−2.67≤m(Zr)≤3.48m(B)−1.87 in which m(B) (mass %) is B content and m(Zr) (mass %) is Zr content.

The present disclosure provides a method for manufacturing a multi-main-phase structure magnet having excellent coercive force and a multi-main-phase structure magnet manufactured therefrom.

A wireless power transfer device includes a first transmitting coil oriented along a first axis and including a first ferrite rod; a second transmitting coil on the first transmitting coil, oriented along a second axis different from the first axis, and including a second ferrite rod; and a nonmagnetic layer magnetically decoupling the first ferrite rod from the second ferrite rod in an area of overlap between the first and second ferrite rods, the first ferrite rod and the nonmagnetic layer being fabricated utilizing additive manufacturing.

A permanent magnet formed by additively manufacturing magnetic phases and buffer phases is disclosed. The buffer phase(s) may improve performance, enhance mechanical properties and allow the magnet to better tolerate stresses such that defects such as cracking do not occur or are less likely to occur. The buffer phase may be a magnetic or non-magnetic material.