Sub-micron particles of rare earth and transition metals and alloys, including rare earth magnet materials
AssigneeNoveon Magnetics Inc.
InventorsMiha Zakotnik, Davide Prosperi, Gojmir Furlan, Catalina O. Tudor, Alex Ivor Bevan
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Abstract
The present disclosure is directed to methods of preparing substantially spherical metallic alloyed particles, having micron and sub-micron (i.e., nanometer)-scaled dimensions, and the powders so prepared, as well as articles derived from these powders. In particular embodiments, these metallic alloyed particles, comprising rare earth metals, can be prepared in sizes as small 80 nm in diameter with size variances as low as 2-5%.
Claims14
A method comprising impinging at least one inert fluid stream having a velocity of 0.2-10.5 km/sec onto a stream of a molten or liquid metallic alloy under appropriate conditions so as to produce a dispersion of substantially spherical solid particles of the metallic alloy within the at least one inert fluid stream, the particles having a mean particle size in a range of 80 nm to 500 microns;
- and wherein the molten or liquid metallic alloy is represented by the formula NdjDykComCunFep, wherein:
- j is atomic percent in a range from 1 to 20 atom %, relative to the entire composition;
- k is atomic percent in a range from 1 to 60 atom %, relative to the entire composition;
- m is atomic percent in a range from 1 to 60 atom %, relative to the entire composition;
- n is atomic percent in a range from 0.1 to 20 atom %, relative to the entire composition;
- p is atomic percent in a range from 1 to 20 atom %, relative to the entire composition;
- and
- j, k, m, n, and p are independently variable within their stated ranges provided that the sum of j+k+m+n+p is greater than 95 atom %.
Dependencies are inferred from the claim text.