US 6,352,599 B1Granted

High performance iron-rare earth-boron-refractory-cobalt nanocomposite

AssigneeSantoku Corporation

InventorsWen Cheng Chang, Bao-Min Ma, Qun Chen, Charles O. Bounds

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Abstract

Magnetic nanocomposite materials including iron, rare earth elements, boron, refractory metals and cobalt which have favorable magnetic properties and are suitable for making bonded magnets are disclosed. Compositions of the present invention can be of the formula: (N1−yLay)vFe100−v−w−x−zCowMzBx, where M is at least one refractory metal selected from Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W; v is from about 5 to about 15; w is greater than or equal to 5; x is from about 9 to about 30; y is from about 0.05 to about 0.5; and z is from about 0.1 to about 5. Preferably M is at least Cr. These materials have good magnetic properties and are suitable for use in preparing bonded magnets.

Claims25

Dependent claims

A permanent magnet material characterized by a chemical formula:

(RE1−yLay)vFe100−v−w−x−zCow Mz Bx,
wherein
RE is at least one element selected from the group consisting of Pr and Nd;
M is Cr;
v is from about 9.5 to about 11.5
w is from about 5 to about 12
x is from about 9 to about 11.5
y is from about 0.05 to about 0.1
z is from about 2 to about 3
the magnet material having been made by rapid cooling from a molten state at a cooling rate between 104 to 107 degrees C./second to make a substantially amorphous material, followed by thermal treating at temperatures from about 600 to 750 degrees C. for 0.01 seconds to 120 minutes,
the material containing the following phases:
(i) a hard magnetic phase comprising at least one member of the group consisting of RE2Fe14B and RE2(Fe,Co)14B,
(ii) a soft magnetic phase comprising at least one member of the group consisting of α-Fe, Fe3B, and α-(Fe,Co),
(iii) one or more metal M boride precipitated phases.

11 more elements

Dependencies are inferred from the claim text.