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 (AlFeSi) alloy. The first crystalline phase is a predominant phase in the crystalline AlFeSi 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 (AlFeSi) alloy. The first crystalline phase is a predominant phase in the crystalline AlFeSi alloy.

A composite is obtained by press-molding a mixed powder comprising 20-50 vol % of a metal powder and 50-80 vol % of a diamond powder for which a first peak in a volumetric distribution of particle size lies at 5-25 m, and a second peak lies at 55-195 m, and a ratio between the area of a volumetric distribution of particle sizes of 1-35 m and the area of a volumetric distribution of particle sizes of 45-205 m is from 1:9 to 4:6, thereby obtaining a composite having a high thermal conductivity and a coefficient of thermal expansion close to that of semiconductor devices, which is easy to mold into a prescribed shape.

A composite is obtained by press-molding a mixed powder comprising 20-50 vol % of a metal powder and 50-80 vol % of a diamond powder for which a first peak in a volumetric distribution of particle size lies at 5-25 m, and a second peak lies at 55-195 m, and a ratio between the area of a volumetric distribution of particle sizes of 1-35 m and the area of a volumetric distribution of particle sizes of 45-205 m is from 1:9 to 4:6, thereby obtaining a composite having a high thermal conductivity and a coefficient of thermal expansion close to that of semiconductor devices, which is easy to mold into a prescribed shape.

Provided are: a method for manufacturing a sintered body as a base of a sintered magnet and a method for manufacturing a permanent magnet. Specifically, a magnet raw material is pulverized into magnet powder, the magnet powder pulverized and a binder are mixed, thereby to form a compound. The, a formed body, obtained by forming the compound formed, is sintered by heating up the same to a firing temperature in a pressed state at a predetermined heat-up rate, and by keeping the same at the firing temperature. In the sintering step, the pressure value for pressing the formed body is set to: less than 3 MPa from the start of heating up of the formed body to a predetermined timing during heating up of the formed body; and 3 MPa or more after the timing.

Provided are: a method for manufacturing a sintered body as a base of a sintered magnet and a method for manufacturing a permanent magnet. Specifically, a magnet raw material is pulverized into magnet powder, the magnet powder pulverized and a binder are mixed, thereby to form a compound. The, a formed body, obtained by forming the compound formed, is sintered by heating up the same to a firing temperature in a pressed state at a predetermined heat-up rate, and by keeping the same at the firing temperature. In the sintering step, the pressure value for pressing the formed body is set to: less than 3 MPa from the start of heating up of the formed body to a predetermined timing during heating up of the formed body; and 3 MPa or more after the timing.

A method of manufacturing a pressed powder magnetic core disclosed herein may include: mixing soft magnetic metal particles, low-melting-point glass particles and lubricant and heating a mixture of the soft magnetic metal particles, the low-melting-point glass particles and the lubricant at a temperature that is higher than a melting point of the lubricant and is lower than a softening point of the low-melting-point glass particles so as to obtain powder of coated metal particles in which surfaces of the soft magnetic metal particles are coated by the lubricant and the low-melting-point glass particles are distributed in coating layers of the lubricant; filling a mold with the powder; press-molding the powder in the mold; and annealing the press-molded powder. In the pressed powder magnetic core, an amount of the low-melting-point glass particles may be 0.1 wt % to 5.0 wt % relative to an amount of the soft magnetic metal particles.

A method of manufacturing a pressed powder magnetic core disclosed herein may include: mixing soft magnetic metal particles, low-melting-point glass particles and lubricant and heating a mixture of the soft magnetic metal particles, the low-melting-point glass particles and the lubricant at a temperature that is higher than a melting point of the lubricant and is lower than a softening point of the low-melting-point glass particles so as to obtain powder of coated metal particles in which surfaces of the soft magnetic metal particles are coated by the lubricant and the low-melting-point glass particles are distributed in coating layers of the lubricant; filling a mold with the powder; press-molding the powder in the mold; and annealing the press-molded powder. In the pressed powder magnetic core, an amount of the low-melting-point glass particles may be 0.1 wt % to 5.0 wt % relative to an amount of the soft magnetic metal particles.

A grain boundary diffusion method for a rare-earth (RE) magnet is provided. The method includes coating particles of the RE magnet with a coating material. Each RE magnet particle includes a plurality of grains. The coated particles are then simultaneously heat treated and compacted. The heat treated, compacted, and coated particles are then formed into a rare earth magnet. In a form of the method, the heat treated, compacted, and coated particles are hot deformed prior to being formed into a rare earth magnet. Another form of the method achieves the grain boundary diffusion without first sintering the rare earth magnet.

A grain boundary diffusion method for a rare-earth (RE) magnet is provided. The method includes coating particles of the RE magnet with a coating material. Each RE magnet particle includes a plurality of grains. The coated particles are then simultaneously heat treated and compacted. The heat treated, compacted, and coated particles are then formed into a rare earth magnet. In a form of the method, the heat treated, compacted, and coated particles are hot deformed prior to being formed into a rare earth magnet. Another form of the method achieves the grain boundary diffusion without first sintering the rare earth magnet.