A rotating electric machine according to embodiments is a rotating electric machine including a rotor including a first core and being capable of rotating around a rotating shaft; and a stator disposed to face the rotor in the axial direction of the rotating shaft, the first core including a first pressed powder material having a plurality of first flaky magnetic metal particles and a first intercalated phase, the first flaky magnetic metal particles having an average thickness of from 10 nm to 100 μm, each first flaky magnetic metal particle having a first flat surface and a first magnetic metal phase including at least one first element selected from the group consisting of Fe, Co, and Ni, the average value of the ratio of the average length in the first flat surface with respect to the average thickness being from 5 to 10,000, the first intercalated phase existing between the first flaky magnetic metal particles and including at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F), wherein in the first pressed powder material, the first flat surfaces are oriented approximately in parallel with a first principal plane of the first pressed powder material and have the difference in magnetic permeability on the basis of direction within the first principal plane, and the first principal plane of the first pressed powder material is disposed to be approximately perpendicular to the radial direction of the rotating electric machine.

A grain boundary diffusion method for a bulk rare earth permanent magnetic material includes the following steps: (1) fabricating an initial magnet by a sintering, hot pressing, or hot deformation process; (2) loading a grain boundary diffusion alloy source on a surface of the magnet through electrodeposition, chemical vapor deposition (CVD), physical vapor deposition (PVD), direct physical contact, or adhesive bonding; and (3) placing the initial magnet loaded with the grain boundary diffusion alloy source in a SPS device, and heating to obtain a final magnet. The current, plasma, and pressure in an SPS process can be controlled to significantly improve elemental diffusion coefficient and enhance the diffusion depth. The bulk rare earth permanent magnetic material undergoing grain boundary diffusion fabricated in the present disclosure has a significant increase in magnetic properties that catering to commercial demands for industrial production.

There is provided a compact for a magnet which can produce a magnetic member having high coercive force. The compact for a magnet is produced by compression-molding a rare earth-iron-based alloy powder containing a plurality of particles of a rare earth-iron-based alloy containing a rare earth element and iron, wherein the rare earth-iron-based alloy satisfies configurations (a) to (c) below and has 5% by volume or more and 20% by volume or less of voids formed therein. (a) Having a structure containing 10% by mass or more and 30% by mass or less of Sm, 10% by mass or less of Mn, and the balance consisting of Fe and inevitable impurities. (b) A composition, Sm.sub.2MN.sub.xFe.sub.17-x (x=0.1 or more and 2.5 or less). (c) An average crystal grain diameter of 700 nm or less.

Nanocomposite magnetic materials, methods of manufacturing nanocomposite magnetic materials, and magnetic devices and systems using these nanocomposite magnetic materials are described. A nanocomposite magnetic material can be formed using an electro-infiltration process where nanomaterials (synthesized with tailored size, shape, magnetic properties, and surface chemistries) are infiltrated by electroplated magnetic metals after consolidating the nanomaterials into porous microstructures on planar substrates. The nanomaterials may be considered the inclusion phase, and the magnetic metals may be considered the matrix phase of the multi-phase nanocomposite.

According to an embodiment, a composite permanent magnet includes a matrix of magnetically hard phase grains having an average grain size of 10 nm to 50 μm; and magnetically soft phase grains embedded within the matrix, and having an average grain size of at least 50 nm, each grain having an elongated shape with an aspect ratio of at least 2:1. According to another embodiment, a composite permanent magnet includes a matrix of magnetically hard phase grains having an average grain size of 10 nm to 50 μm; and magnetically soft phase grains embedded within the matrix, and having an average grain width of at least 50 nm, an average grain height of 20 to 500 nm, and an aspect ratio of at least 2:1. According to yet another embodiment, a method of forming a composite permanent magnet is also provided.

A permanent magnet comprises crystal grains each including a main phase. An average size of the crystal grains is 1.0 μm or less, and a degree of orientation of easy magnetization axes of the crystal grains to an easy magnetization axis of the magnet is 15% or more and 90% or less. A recoil magnetic permeability is 1.13 or more, a residual magnetization is 0.8 T or more and less than 1.16 T, and an intrinsic coercive force is 850 kA/m or more.

In a sintered rare-earth magnet containing R.sub.2T.sub.14B main-phase grains (R being one or more element selected from rare-earth elements and T being one or more element selected from iron group elements), intergranular grain boundaries that from between two mutually adjoining main-phase grains and grain boundary triple junctions surrounded by three or more main-phase grains, the main-phase grains, the intergranular grain boundaries and the grain boundary triple junctions all include TiB.sub.2 crystals. The sintered rare-earth magnet is a to high-performance magnet of high coercivity and good squareness.

In one embodiment, a magnet includes a three-dimensional structure with nanoscale features, where the three-dimensional structure has a near net shape corresponding to a predefined shape.

There is provided a manufacturing method for a rare earth magnet, including forming a zinc-containing coating film on a surface of a particle of a samarium-iron-nitrogen-based magnetic powder to obtain a coated powder, subjecting the coated powder to compression molding to obtain a compacted powder body, and subjecting the compacted powder body to pressure sintering, in which a coating rate of the coating film with respect to an entire surface of the particle of the coated powder is 96% or more, and the formation of the coating film and the pressure sintering of the compacted powder body is carried out in a vacuum or an inert gas atmosphere, and the compression molding of the coated powder is carried out in the atmospheric air.

A rotating electric machine according to embodiments is a rotating electric machine including a rotor including a first core and being capable of rotating around a rotating shaft; and a stator disposed to face the rotor in the axial direction of the rotating shaft, the first core including a first pressed powder material having a plurality of first flaky magnetic metal particles and a first intercalated phase, the first flaky magnetic metal particles having an average thickness of from 10 nm to 100 μm, each first flaky magnetic metal particle having a first flat surface and a first magnetic metal phase including at least one first element elected from the group consisting of Fe, Co, and Ni, the average value of the ratio of the average length in the first flat surface with respect to the average thickness being from 5 to 10,000, the first intercalated phase existing between the first flaky magnetic metal particles and including at least one second element selected from the group consisting of oxygen (O), carbon (C), nitrogen (N), and fluorine (F), wherein in the first pressed powder material, the first flat surfaces are oriented approximately in parallel with a first principal plane of the first pressed powder material and have the difference in magnetic permeability on the basis of direction within the first principal plane, and the first principal plane of the first pressed powder material is disposed to be approximately perpendicular to the radial direction of the rotating electric machine.