Processes for refurbishing a spent sputtering target with a non-circular shape are disclosed. In one form, the processes include the steps of receiving one or more spent sputtering targets, inspecting and weighing the spent sputtering targets, removing any contaminants or other surface impurities from the spent sputtering target surfaces, preparing a hot press die with spacers, disposing the spent sputtering targets in the hot press die, the spacers used to center the spent sputtering targets therein, loading fresh metal refilling powder into the die to account for depleted regions of the spent sputtering targets to produce a powder-filled sputtering target, and applying sufficient heat and force to the filled sputtering target to produce a refurbished sputtering target with homogeneous composition and sufficient adhesion strength.

A method of manufacturing a crystalline aluminum-iron-silicon alloy and a crystalline aluminum-iron-silicon alloy part. An aluminum-, iron-, and silicon-containing composite powder is provided that includes an amorphous phase and a first crystalline phase having a hexagonal crystal structure at ambient temperature. The composite powder is heated at a temperature in the range of 850° C. to 950° C. to transform at least a portion of the amorphous phase into the first crystalline phase and to transform the composite powder into a crystalline aluminum-iron-silicon (Al—Fe—Si) alloy. The first crystalline phase is a predominant phase in the crystalline Al—Fe—Si alloy.

A method of manufacturing a crystalline aluminum-iron-silicon alloy and a crystalline aluminum-iron-silicon alloy part. An aluminum-, iron-, and silicon-containing composite powder is provided that includes an amorphous phase and a first crystalline phase having a hexagonal crystal structure at ambient temperature. The composite powder is heated at a temperature in the range of 850° C. to 950° C. to transform at least a portion of the amorphous phase into the first crystalline phase and to transform the composite powder into a crystalline aluminum-iron-silicon (Al—Fe—Si) alloy. The first crystalline phase is a predominant phase in the crystalline Al—Fe—Si alloy.

Methods for producing final bodies that contain a fine-grained refractory complex concentrated alloy (RCCA), as well as RCCAs, intermediate materials and final bodies containing the RCCAs, and high-temperature devices formed by such final bodies. Such a method includes providing a precursor with one or more precursor compounds containing elements of an RCCA, reducing the precursor compounds in the precursor via reaction with a reducing agent so as to generate the RCCA and a compound comprising a product of the reaction between the reducing agent and the precursor compounds, generating a solid material that contains at least the RCCA, forming with the solid material a porous intermediate body, and consolidating the porous intermediate body so as to partially or completely remove the pore volume from the porous intermediate body, and in doing so yield either a denser final body or a denser film.

A magnetic material of the embodiments is a magnetic material including: a plurality of flaky magnetic metal particles, each flaky magnetic metal particle having a flat surface and amagneticmetalphase containing at least one first element selected from the group consisting of Fe, Co, and Ni, the flaky magnetic metal particles having an average thickness of from 10 nm to 100 m and having an average value of the ratio of the average length in the flat surface to the thickness of from 5 to 10,000; and an intercalated phase existing between the flaky magnetic metal particles and containing at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F), in which the magnetic material includes the intercalated phase at a volume ratio of from 4% to 17% and includes voids at a volume ratio of 30% or less, and an average angle of orientation between the flat surface and a plane of the magnetic material is 10 or less.

A magnetic material of the embodiments is a magnetic material including: a plurality of flaky magnetic metal particles, each flaky magnetic metal particle having a flat surface and amagneticmetalphase containing at least one first element selected from the group consisting of Fe, Co, and Ni, the flaky magnetic metal particles having an average thickness of from 10 nm to 100 m and having an average value of the ratio of the average length in the flat surface to the thickness of from 5 to 10,000; and an intercalated phase existing between the flaky magnetic metal particles and containing at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F), in which the magnetic material includes the intercalated phase at a volume ratio of from 4% to 17% and includes voids at a volume ratio of 30% or less, and an average angle of orientation between the flat surface and a plane of the magnetic material is 10 or less.

Powder particles for forming a homogeneous green body having a sufficient strength and a process for producing a green body by using the powder particles. A green body is shaped by using powder particles of composite particles in which thermoplastic resin particles are scattered on surfaces of large particles in an amount within a predetermined volume ratio range with respect to the large particles, and loaded to form resin pools in contact point peripheral areas of adjoining ones of the large particles and form voids in areas other than the contact point peripheral areas when the thermoplastic resin particles are melted. A green body packed with the powder particles each having a small amount of the thermoplastic resin particles attached thereon is placed under a melting condition of the thermoplastic resin particles, the thermoplastic resin is melted and gathers around contact points (or proximal points) of the adjoining powder particles.

A composite magnetic body according to one aspect of the present invention includes a first metal magnetic particle covered with a first resin portion made of a first resin material and a second metal magnetic particle having a smaller particle size than the first metal magnetic particle, where the second metal magnetic particle is bound to the first metal magnetic particle via a second resin portion made of a second resin material and the second resin material has a larger molecular weight than the first resin material.

A composite magnetic body according to one aspect of the present invention includes a first metal magnetic particle covered with a first resin portion made of a first resin material and a second metal magnetic particle having a smaller particle size than the first metal magnetic particle, where the second metal magnetic particle is bound to the first metal magnetic particle via a second resin portion made of a second resin material and the second resin material has a larger molecular weight than the first resin material.

Disclosed are interfacially modified metal particulate composite materials for use in powder metallurgy sintered products and processes.