Thermally stable, cladded permanent magnets, and compositions and methods for making the same

Abstract

The disclosed technology provides a nanofunctionalized magnetic material feedstock comprising: from 50 wt % to 99.5 wt % of magnetic microparticles having an average microparticle effective diameter from 1 micron to 500 microns; from 0.4 wt % to 40 wt % of one or more rare earth elements; and from 0.1 wt % to 10 wt % of metal-containing grain-refining nanoparticles, wherein at least 1 wt % of the grain-refining nanoparticles are chemically and/or physically disposed on surfaces of the magnetic microparticles. The nanofunctionalized magnetic material feedstock is processed using high-throughput laser-based additive manufacturing to optimize the architecture of NdFeB or other magnets, generating site-specific, demagnetization-resistant microstructures. This disclosure teaches a rapid, single-step laser-based process to tailor the easy axis alignment, grain size, and microstructure of a permanent magnet at corners and edges to resist demagnetization.

Dependencies are inferred from the claim text.