A sintered magnet contains Sm—Fe—N-based crystal grains and has high coercivity; and a magnetic powder is capable of forming a sintered magnet without lowering the coercivity even if heat is generated in association with the sintering. A sintered magnet comprises a crystal phase composed of a plurality of Sm—Fe—N-based crystal grains and a nonmagnetic metal phase present between the Sm—Fe—N crystal grains adjacent to each other, wherein a ratio of Fe peak intensity I.sub.Fe to SmFeN peak intensity I.sub.SmFeN measured by an X-ray diffraction method is 0.2 or less. A magnetic powder comprises Sm—Fe—N-based crystal particles and a nonmagnetic metal layer covering surfaces of the Sm—Fe—N crystal particles.

A method for producing a powdered starting material, which is provided for production of rare earth magnets, including includes the following steps: pulverizing an alloy, including at least one rare earth metal, wherein a powdered intermediate product is formed from the alloy including the at least one rare earth metal, and carrying out at least one classification aimed at particle size and/or particle density for the powdered intermediate product. A fraction of the powdered intermediate product, which is formed by the at least one classification, is used for fabrication of rare earth magnets. Furthermore, at least one dynamic classifier is provided, implementing at least one classification directed at particle size and/or particle density for the powdered intermediate product and thereby separates the fraction from the powdered intermediate product, which forms the starting material for manufacturing rare earth magnets.

A method for producing a powdered starting material, which is provided for production of rare earth magnets, including includes the following steps: pulverizing an alloy, including at least one rare earth metal, wherein a powdered intermediate product is formed from the alloy including the at least one rare earth metal, and carrying out at least one classification aimed at particle size and/or particle density for the powdered intermediate product. A fraction of the powdered intermediate product, which is formed by the at least one classification, is used for fabrication of rare earth magnets. Furthermore, at least one dynamic classifier is provided, implementing at least one classification directed at particle size and/or particle density for the powdered intermediate product and thereby separates the fraction from the powdered intermediate product, which forms the starting material for manufacturing rare earth magnets.

A method for producing a powdered starting material, which is provided for production of rare earth magnets, including the following steps: pulverizing an alloy, including at least one rare earth metal, wherein a powdered intermediate product is formed from the alloy including at least one rare earth metal, and carrying out at least one classification aimed at particle size and/or density for the powdered intermediate product, wherein a fraction of the powdered intermediate product, which is formed by means of the at least one classification, for fabrication of rare earth magnets. Furthermore, at least one dynamic classifier is provided, implementing at least one classification directed at particle size and/or density for the powdered intermediate product and thereby separates the fraction from the powdered intermediate product, which forms the starting material provided for manufacturing rare earth magnets.

A method for producing a powdered starting material, which is provided for production of rare earth magnets, including the following steps: pulverizing an alloy, including at least one rare earth metal, wherein a powdered intermediate product is formed from the alloy including at least one rare earth metal, and carrying out at least one classification aimed at particle size and/or density for the powdered intermediate product, wherein a fraction of the powdered intermediate product, which is formed by means of the at least one classification, for fabrication of rare earth magnets. Furthermore, at least one dynamic classifier is provided, implementing at least one classification directed at particle size and/or density for the powdered intermediate product and thereby separates the fraction from the powdered intermediate product, which forms the starting material provided for manufacturing rare earth magnets.

A sintered magnet contains SmFeN-based crystal grains and has high coercivity; and a magnetic powder is capable of forming a sintered magnet without lowering the coercivity even if heat is generated in association with the sintering. A sintered magnet comprises a crystal phase composed of a plurality of SmFeN-based crystal grains and a nonmagnetic metal phase present between the SmFeN crystal grains adjacent to each other, wherein a ratio of Fe peak intensity I.sub.Fe to SmFeN peak intensity I.sub.SmFeN measured by an X-ray diffraction method is 0.2 or less. A magnetic powder comprises SmFeN-based crystal particles and a nonmagnetic metal layer covering surfaces of the SmFeN crystal particles.

A method for producing a powdered starting material, which is provided for production of rare earth magnets, including the following steps: pulverizing an alloy, including at least one rare earth metal, wherein a powdered intermediate product is formed from the alloy including at least one rare earth metal, and carrying out at least one classification aimed at particle size and/or density for the powdered intermediate product, wherein a fraction of the powdered intermediate product, which is formed by means of the at least one classification, for fabrication of rare earth magnets. Furthermore, at least one dynamic classifier is provided, implementing at least one classification directed at particle size and/or density for the powdered intermediate product and thereby separates the fraction from the powdered intermediate product, which forms the starting material provided for manufacturing rare earth magnets.

A method for producing a powdered starting material, which is provided for production of rare earth magnets, including the following steps: pulverizing an alloy, including at least one rare earth metal, wherein a powdered intermediate product is formed from the alloy including at least one rare earth metal, and carrying out at least one classification aimed at particle size and/or density for the powdered intermediate product, wherein a fraction of the powdered intermediate product, which is formed by means of the at least one classification, for fabrication of rare earth magnets. Furthermore, at least one dynamic classifier is provided, implementing at least one classification directed at particle size and/or density for the powdered intermediate product and thereby separates the fraction from the powdered intermediate product, which forms the starting material provided for manufacturing rare earth magnets.

The present invention is a method capable of producing a rare-earth magnet with excellent magnetization and coercivity. The method includes producing a sintered body including a main phase and grain boundary phase and represented by (R1.sub.1-xR2.sub.x).sub.aTM.sub.bB.sub.cM.sub.d (where R1 represents one or more rare-earth elements including Y, R2 represents a rare-earth element different than R1, TM represents transition metal including at least one of Fe, Ni, or Co, B represents boron, M represents at least one of Ti, Ga, Zn, Si, Al, etc., 0.01x1, 12a20, b=100acd, 5c20, and 0d3 (all at %)); applying hot deformation processing to the sintered body to produce a precursor of the magnet; and diffusing/infiltrating melt of a R3-M modifying alloy (rare-earth element where R3 includes R1 and R2) into the grain boundary phase of the precursor.

Magnets and systems, methods, and techniques for manufacturing magnets are provided. In some embodiments, methods of manufacturing magnets comprise providing a rare earth magnetic body, cold spray depositing a layer of dysprosium or terbium onto the magnetic body to form a magnet, and heat-treating the magnet. Some embodiments provide a magnet comprising a magnetic body and a layer of dysprosium or terbium. In some embodiments, the magnetic body contains grains of rare earth magnet alloy, and the layer of dysprosium or terbium is deposited onto a surface of the magnetic body by a cold spray process.