Powdered metals and structural metals having improved resistance to heat and corrosive fluids and b-stage powders for making such powdered metals

A flowable B-stage material curable to a component of predetermined shape having improved stability upon contact with corrosive liquids, the flowable B-stage material comprising:

• a. a particulate material;
• and
• b. a curable resin system at least partially coating the particulate material, the resin system being curable to a resin having a high crosslink density and a low concentration of hydrolysable moieties.

A electric fuel pump adapted for operation submerged in a corrosive fuel containing a high concentration of ethanol, the electric fuel pump comprising a shaped, magnetic powdered metal component comprising about 97.7% by weight of an Nd—Fe—B particulate material consisting essentially of Nd2Fe14B having an average particle size of about 150 microns bound in about 2.3% by weight of a heat cured resin binder system comprising about four parts phenyl novolac resin crosslinked with about one part diamine hardener.

A method for protecting a material from a corrosive fluid comprising:

• a. coating at least a portion of the material with an effective amount of a curable resin system that when cured has a relatively high crosslink density and a relatively low hydrolysable content;
• and
• b. curing the resin system.