Atomization methods for forming magnet powders

An atomization method for forming a magnet powder comprising:

• forming a melt comprising Nd.sub.2.1 Fe.sub.13.9 B.sub.1, Ti and X, wherein X is oxygen, wherein the weight percentage of the combination of Ti and X is from about 0.1% to about 15%, and wherein the Ti and X are present in substantially equal molar amounts;
• atomizing the melt, the atomizing including forming an atomized melt and cooling the atomized melt at a rate of less than or equal to about 100,000.degree. C./second to form generally spherical alloy powder granules having an internal structure comprising at least one of a substantially amorphous phase or a substantially nanocrystalline phase;
• and
• heat treating the alloy powder to increase an energy product of the alloy powder.

A method for forming a magnet powder comprising:

• forming a melt comprising Nd, Q, B, Z, and X wherein X is oxygen;
• Q is an element selected from the group consisting of Fe, Co, and mixtures thereof;
• and Z is an element selected from the group consisting of Ti, Zr, Hf and mixtures thereof;
• atomizing the melt, the atomizing including forming an atomized melt and cooling the atomized melt at a rate of less than or equal to about 100,000.degree. C./second to form alloy powder granules having an internal structure comprising at least one of a substantially amorphous phase or a substantially nanocrystalline phase, the internal structure having a weight percentage of elements selected from the group consisting of iron, cobalt, and mixtures thereof of at least 60%;
• and
• heat treating the alloy powder to increase the energy product of the alloy powder;
• after the heat treatment, the alloy powder possessing an energy product of at least about 10 MGOe.