Nanocomposite magnet and method for producing same

A rapidly solidified alloy having a composition represented by the general formula:

• (Fe1-mTm)100-x-y-z-nQxRyTizMn, where T is at least one element selected from the group consisting of Co and Ni;
• Q is at least one element selected from the group consisting of B and C;
• R is a rare earth element;
• and M is at least one element selected from the group consisting of Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Hf, Ta, W, Pt, Pb, Au and Ag, the mole fractions x, y, z, m and n satisfying the inequalities of:
• 10at %<x≦20 at %;
• 6at %≦y<10 at %;
• 0.5 at %≦z≦6 at %;
• 0≦m≦0.5;
• and
• 0at %≦n≦5 at %, respectively,
• wherein the alloy has a thickness of between about 50 μm and about 200 μm, and
• wherein in the alloy, a crystal structure is located on each of two surfaces thereof that cross a thickness direction approximately at right angles.

A rapidly solidified alloy having a composition represented by the general formula:

• (Fe1-mTm)100-x-y-z-nQxRyTizMn, where T is at least one element selected from the group consisting of Co and Ni;
• Q is at least one element selected from the group consisting of B and C;
• R is a rare earth element;
• and M is at least one element selected from the group consisting of Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Hf, Ta, W, Pt, Pb, Au and Ag, the mole fractions x, y, z, m and n satisfying the inequalities of:
• 10at %<x≦20 at %;
• 6 at %≦y <10 at %;
• 0.5 at %≦z≦6 at %;
• 0m≦0.5;
• and
• 0 at %≦n≦5 at %, respectively,
• wherein the alloy has a thickness of between about 60 μm and about 150 μm, and
• wherein the alloy has a recoil permeability of between about 1.1 and about 2.

A magnet powder having a composition represented by the general formula:

• (Fe1-mTm)100-x-y-z-nQxRyTizMn, where T is at least one element selected from the group consisting of Co and Ni;
• Q is at least one element selected from the group consisting of B and C;
• R is a rare earth element;
• and M is at least one element selected from the group consisting of Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Hf, Ta, W, Pt, Pb, Au and Ag, the mole fractions x, y, z, m and n satisfying the inequalities of:
• 10at %<x≦20 at %;
• 6at %≦y<10 at %;
• 0.5 at %≦z≦6 at %;
• 0≦m≦0.5;
• and
• 0at %≦n≦5 at %, respectively,
• wherein the powder has a mean particle size of between about 60 μm and about 110 μm, and
• wherein a ratio of a major-axis dimension of the powder to a minor-axis dimension thereof is between about 0.3 and about 1, and
• wherein the powder has a coercivity HcJ of about 600 kA/m or more.