Some variations provide a method of making a nanofunctionalized metal powder, comprising: providing metal particles containing metals selected from iron, nickel, copper, titanium, magnesium, zinc, silicon, lithium, silver, chromium, manganese, vanadium, bismuth, gallium, or lead; providing nanoparticles selected from zirconium, tantalum, niobium, or titanium; disposing the nanoparticles onto surfaces of the metal particles, in the presence of mixing media, thereby generating nanofunctionalized metal particles; and isolating and recovering the nanofunctionalized metal particles as a nanofunctionalized metal powder. Some variations provide a composition comprising a nanofunctionalized metal powder, the composition comprising metal particles and nanoparticles containing one or more elements selected from the group consisting of zirconium, tantalum, niobium, titanium, and oxides, nitrides, hydrides, carbides, or borides thereof, or combinations of the foregoing.

Included is a method of preparing a compound for bonded magnets, the method including: coating a magnetic material having an average particle size of 10 μm or less with a thermosetting resin and a curing agent at a ratio of the equivalent weight of the curing agent to the equivalent weight of the thermosetting resin of 2 or higher and 10 or lower to obtain a coated material; granulating the coated material by compression to obtain a granulated product; milling the granulated product to obtain a milled product; and surface treating the milled product with a silane coupling agent to obtain a compound for bonded magnets, the method either including, between the granulation and the milling, heat curing the granulated product to obtain a cured product, or including, between the milling and the surface treatment, heat curing the milled product to obtain a cured product.

Included is a method of preparing a compound for bonded magnets, the method including: coating a magnetic material having an average particle size of 10 μm or less with a thermosetting resin and a curing agent at a ratio of the equivalent weight of the curing agent to the equivalent weight of the thermosetting resin of 2 or higher and 10 or lower to obtain a coated material; granulating the coated material by compression to obtain a granulated product; milling the granulated product to obtain a milled product; and surface treating the milled product with a silane coupling agent to obtain a compound for bonded magnets, the method either including, between the granulation and the milling, heat curing the granulated product to obtain a cured product, or including, between the milling and the surface treatment, heat curing the milled product to obtain a cured product.

A hydrogen storing alloy containing only a few impurities leading to a short circuit where the yield can be maintained even when the alloy is subjected to magnetic separation treatment. A hydrogen storing alloy includes a matrix phase having an AB5 type crystal structure, the alloy having a misch metal (referred to as “Mm”) in an A-site in an ABx composition and having any one or at least one of Ni, Al, Mn, and Co in a B-site in the ABx composition, wherein the ratio (referred to as “ABx”) of the total number of moles of elements comprising the B site to the total number of moles of elements comprising the A site is 5.00<ABx≦5.40; the content of Co is more than 0.0 mol % and less than 0.7 mol %; and residual magnetization is more than 0 emu/g and 0.020 emu/g or less.

A hydrogen storing alloy containing only a few impurities leading to a short circuit where the yield can be maintained even when the alloy is subjected to magnetic separation treatment. A hydrogen storing alloy includes a matrix phase having an AB5 type crystal structure, the alloy having a misch metal (referred to as “Mm”) in an A-site in an ABx composition and having any one or at least one of Ni, Al, Mn, and Co in a B-site in the ABx composition, wherein the ratio (referred to as “ABx”) of the total number of moles of elements comprising the B site to the total number of moles of elements comprising the A site is 5.00<ABx≦5.40; the content of Co is more than 0.0 mol % and less than 0.7 mol %; and residual magnetization is more than 0 emu/g and 0.020 emu/g or less.

Provided herein is a soft magnetic alloy powder that can exhibit a high saturation flux density and desirable soft magnetic characteristics. A dust core using the soft magnetic alloy powder is also provided. The soft magnetic alloy powder is an Fe-based nanocrystalline soft magnetic alloy powder of a crystallized Fe-based amorphous soft magnetic alloy powder, and has a DSC curve with a first peak that is 15% or less of a first peak of the Fe-based amorphous soft magnetic alloy in terms of a maximum value.

Provided herein is a soft magnetic alloy powder that can exhibit a high saturation flux density and desirable soft magnetic characteristics. A dust core using the soft magnetic alloy powder is also provided. The soft magnetic alloy powder is an Fe-based nanocrystalline soft magnetic alloy powder of a crystallized Fe-based amorphous soft magnetic alloy powder, and has a DSC curve with a first peak that is 15% or less of a first peak of the Fe-based amorphous soft magnetic alloy in terms of a maximum value.

The present disclosure generally relates to a method of fabricating a graded metallic structure by additive manufacturing and the graded metallic structure thereof. The method comprises preparing a material powder in a supply container, the material powder is partitioned into a plurality of longitudinal volumes and comprises different metallic powders, performing an additive manufacturing process comprising supplying layers of the material powder from the supply container, displacing the layers of material powder to a fabrication platform and fusing the layers of material powder on the fabrication platform to form the graded metallic structure, wherein at least one longitudinal volume has a varying transverse cross-sectional area and at least one longitudinal volume has a varying longitudinal cross-sectional area, such that the fused metallic powders in the graded metallic structure are graded along the longitudinal and the transverse. This method is proven to be effective to make graded metal parts with composition gradients in two dimensions.

Included is a method of preparing a compound for bonded magnets, the method including: coating a magnetic material having an average particle size of 10 μm or less with a thermosetting resin and a curing agent at a ratio of the equivalent weight of the curing agent to the equivalent weight of the thermosetting resin of 2 or higher and 10 or lower to obtain a coated material; granulating the coated material by compression to obtain a granulated product; milling the granulated product to obtain a milled product; and surface treating the milled product with a silane coupling agent to obtain a compound for bonded magnets, the method either including, between the granulation and the milling, heat curing the granulated product to obtain a cured product, or including, between the milling and the surface treatment, heat curing the milled product to obtain a cured product.

Included is a method of preparing a compound for bonded magnets, the method including: coating a magnetic material having an average particle size of 10 μm or less with a thermosetting resin and a curing agent at a ratio of the equivalent weight of the curing agent to the equivalent weight of the thermosetting resin of 2 or higher and 10 or lower to obtain a coated material; granulating the coated material by compression to obtain a granulated product; milling the granulated product to obtain a milled product; and surface treating the milled product with a silane coupling agent to obtain a compound for bonded magnets, the method either including, between the granulation and the milling, heat curing the granulated product to obtain a cured product, or including, between the milling and the surface treatment, heat curing the milled product to obtain a cured product.