A method for fabrication of an anisotropic magnet comprises placing magnet alloy feedstock particles in a deformable metallic container and thermomechanically working the filled container in a manner to elongate the filled container and reduce its cross-sectional area to consolidate the magnet alloy particles to an elongated shape and impart a preferential grain texture to the consolidated, elongated shape. The consolidated, elongated shape is machined to a near-final magnet shape that has a smaller dimension such as magnet length and that includes a metallic tubular skin thereon.

A method for forming graphene-oxide (GO) embedded with gallium-iron alloy (galfenol) nanoparticles. The method includes submerging galfenol bulk material in a solution comprising deionized water and polyvinylpyrrolidone (PVP). The method includes ablating, a first time, the galfenol bulk material submerged in the solution with a laser. The method includes removing the galfenol bulk material from the solution after ablating with the laser. The method includes drying the galfenol bulk material after removing the galfenol bulk material from the solution. The method includes submerging galfenol bulk material in deionized water after drying the galfenol bulk material. The method includes ablating, a second time, the galfenol bulk material submerged in the deionized water and ablating a second time the galfenol bulk material submerged in the deionized water.

A method for forming graphene-oxide (GO) embedded with gallium-iron alloy (galfenol) nanoparticles. The method includes submerging galfenol bulk material in a solution comprising deionized water and polyvinylpyrrolidone (PVP). The method includes ablating, a first time, the galfenol bulk material submerged in the solution with a laser. The method includes removing the galfenol bulk material from the solution after ablating with the laser. The method includes drying the galfenol bulk material after removing the galfenol bulk material from the solution. The method includes submerging galfenol bulk material in deionized water after drying the galfenol bulk material. The method includes ablating, a second time, the galfenol bulk material submerged in the deionized water and ablating a second time the galfenol bulk material submerged in the deionized water.

A method of manufacturing permanent magnet materials for use in making MnAl-based alloy permanent magnets includes providing an -phase MnAl-based alloy solid feedstock, end-milling the -phase MnAl-based alloy solid feedstock to produce a plurality of severely plastically deformed -phase MnAl-based alloy particulates, and creating the permanent magnet materials by thermally processing the plurality of -phase MnAl-based alloy particulates to produce a plurality of -phase MnAl-based alloy particulates. In addition, the method may further include making a permanent magnet by mixing the -phase MnAl-based alloy particulates with a binder to produce a mixture, and forming the mixture into a desired shaped for the permanent magnet. The forming step may include one or more of injection molding the mixture, compression bonding the mixture, calendering the mixture or extruding the mixture.

The iron alloy particle is a particle including an iron alloy. The particle includes multiple mixed-phase particles, each including nanocrystals of 10 nm or more and 100 nm or less (i.e., from 10 nm to 100 nm) in crystallite size and an amorphous phase; and a grain boundary layer between the mixed-phase particles. Also, the iron alloy has a composition containing Fe, Si, P, B, C, and Cu.

The iron alloy particle is a particle including an iron alloy. The particle includes multiple mixed-phase particles, each including nanocrystals of 10 nm or more and 100 nm or less (i.e., from 10 nm to 100 nm) in crystallite size and an amorphous phase; and a grain boundary layer between the mixed-phase particles. Also, the iron alloy has a composition containing Fe, Si, P, B, C, and Cu.