This disclosure is directed to methods for creating recycled NdFeB type permanent magnets, the methods comprising homogenizing a first population of particles of a rare earth transitional elemental additive with a second population of particles of a magnetic material, wherein the nature of the rare earth transitional elemental additive and the magnetic material are described herein. Additional steps may include compressing the population of homogenized particles together to form a green body, and heating the green body at a temperature and for a time sufficient to sinter the green body into a sintered body. Compositions resulting from these methods are also within the scope of the disclosure.

This disclosure is directed to methods for creating recycled NdFeB type permanent magnets, the methods comprising homogenizing a first population of particles of a rare earth transitional elemental additive with a second population of particles of a magnetic material, wherein the nature of the rare earth transitional elemental additive and the magnetic material are described herein. Additional steps may include compressing the population of homogenized particles together to form a green body, and heating the green body at a temperature and for a time sufficient to sinter the green body into a sintered body. Compositions resulting from these methods are also within the scope of the disclosure.

Alloy powder of a composition formula Fe.sub.100-a-b-c-d-e-fCo.sub.aB.sub.bSi.sub.cP.sub.dCu.sub.eC.sub.f having an amorphous phase as a main phase is provided. Parameters satisfy the following conditions: 3.5a4.5 at %, 6b15 at %, 2c11 at %, 3d5 at %, 0.5e1.1 at %, and 0f2 at %. With this composition, the alloy powder has good magnetic characteristics even when it has a large particle diameter such as 90 m. Therefore, yield thereof is improved.

Alloy powder of a composition formula Fe.sub.100-a-b-c-d-e-fCo.sub.aB.sub.bSi.sub.cP.sub.dCu.sub.eC.sub.f having an amorphous phase as a main phase is provided. Parameters satisfy the following conditions: 3.5a4.5 at %, 6b15 at %, 2c11 at %, 3d5 at %, 0.5e1.1 at %, and 0f2 at %. With this composition, the alloy powder has good magnetic characteristics even when it has a large particle diameter such as 90 m. Therefore, yield thereof is improved.

A soft magnetic alloy powder includes a first pulverized powder which has a particle diameter of 20 m or more, a value of major diameter/minor diameter of 1.2 or more and 1.8 or less, and a flat plate shape, and a second pulverized powder which has a particle diameter of less than 3 m, a value of major diameter/minor diameter of 1.1 or more and 1.6 or less, and a flat plate shape. A production method of a soft magnetic alloy powder, includes first processing of processing a soft magnetic alloy ribbon into a coarse powder, and second processing of pulverizing the coarse powder with a pulverizer.

The present invention discloses manufacturing methods of a powder for compacting rare earth magnet powder and rare earth magnet that omit jet milling process, which comprises the steps as follows: 1) casting: casting the molten alloy of rare earth magnet raw material by strip casting method to obtain a quenched alloy with average thickness in a range of 0.20.4 mm; 2) hydrogen decrepitation: decrepitating the quenched alloy and a plurality of rigid balls into a rotating hydrogen decrepitation container simultaneously, the quenched alloy is crushed under a hydrogen pressure between 0.011 MPa, cooling the alloy and the balls, then screening the mixture to remove the rigid balls and obtain the powder. As the jet milling process is omitted, the oxygenation during the process of the jet milling may be avoided, therefore the process may be non-oxide, and the mass production of magnet with super high property may be possible.

The present invention discloses manufacturing methods of a powder for compacting rare earth magnet powder and rare earth magnet that omit jet milling process, which comprises the steps as follows: 1) casting: casting the molten alloy of rare earth magnet raw material by strip casting method to obtain a quenched alloy with average thickness in a range of 0.20.4 mm; 2) hydrogen decrepitation: decrepitating the quenched alloy and a plurality of rigid balls into a rotating hydrogen decrepitation container simultaneously, the quenched alloy is crushed under a hydrogen pressure between 0.011 MPa, cooling the alloy and the balls, then screening the mixture to remove the rigid balls and obtain the powder. As the jet milling process is omitted, the oxygenation during the process of the jet milling may be avoided, therefore the process may be non-oxide, and the mass production of magnet with super high property may be possible.

A soft magnetic alloy has a main component of Fe. The soft magnetic alloy contains P. A Fe-rich phase and a Fe-poor phase are contained. An average concentration of P in the Fe-poor phase is 1.5 times or larger than an average concentration of P in the soft magnetic alloy by number of atoms.

A soft magnetic alloy has a main component of Fe. The soft magnetic alloy contains P. A Fe-rich phase and a Fe-poor phase are contained. An average concentration of P in the Fe-poor phase is 1.5 times or larger than an average concentration of P in the soft magnetic alloy by number of atoms.

An iron powder and method of making an iron powder. The method includes a step of neutralizing an acidic aqueous solution containing a trivalent iron ion and a phosphorus-containing ion, with an alkali aqueous solution, so as to provide a slurry of a precipitate of a hydrated oxide, or a step of adding a phosphorus-containing ion to a slurry containing a precipitate of a hydrated oxide obtained by neutralizing an acidic aqueous solution containing a trivalent iron ion with an alkali aqueous solution. A silane compound is added to the slurry so as to coat a hydrolysate of the silane compound on the precipitate of the hydrated oxide. The precipitate of the hydrated oxide after coating is recovered through solid-liquid separation, the recovered precipitate is heated to provide iron particles coated with a silicon oxide, and a part or the whole of the silicon oxide coating is dissolved and removed.