Cerium misch-metal/cobalt magnets

Claim 2

A magnetic material of the formula (CeMM 1-x Ce x ) 1-y Sm y Co 5 ±0.2, wherein 0.05 < x < 0.25 and 0 ≦ y ≦ 0.25 and CeMM is a cerium misch-metal of the formula Ce.sub.α La.sub.β Nd.sub.γ Pr.sub.δ, wherein 0.45 < α < 0.55 0.20 < β < 0.40 0.05 < γ < 0.15 0.00 < δ < 0.05 and α + β + γ + δ ≃ 1 wherein the added quantities of Ce added are within the range at which the coercive field strength is increased and less than the quantity at which the coercive field strength deteriorates.

Claim 3

The magnetic material of claim 1, wherein α, β, γ, and δ are approximately 0.54, 0.30, 0.12 and 0.04, respectively.

Claim 4

A magnetic material of the formula (CeMM 1-x La x ) 1-y Sm y Co 5 ±0.2, wherein 0.15 < x < 0.50 and 0 ≦ y ≦ 0.25 and CeMM is a cerium misch-metal of the formula Ce.sub.α La.sub.β Nd.sub.γ Pr.sub.δ, wherein 0.45 < α < 0.55 0.20 < β < 0.40 0.05 < γ < 0.15 0.00 < δ < 0.05 and α+ β + γ + δ ≃ 1 wherein the added quantities of La added are within the range at which the coercive field strength is increased and less than the quantity at which the coercive field strength detoriorates.

Claim 5

A magnetic material of the formula (CeMM 1-x La x ) 1-y Sm y Co 5 ±0.2, wherein 0.15 < x < 0.50 and 0 ≦ y ≦ 0.25 and CeMM is a cerium misch-metal of the formula Ce.sub.α La.sub.β Nd.sub.γ Pr.sub.δ, wherein 0.45 < α < 0.55 0.20 < β < 0.40 0.05 < γ < 0.15 0.00 < δ < 0.05 and α+ β + γ + δ ≃ 1 wherein the added quantities of La added are within the range at which the coercive field strength is increased and less than the quantity at which the coercive field strength detoriorates.

Claim 6

The magnetic material of claim 3, wherein α, β, γ, and δ are approximately 0.54, 0.30, 0.12 and 0.04, respectively.

Claim 7

A magnetic material of the formula (CeMM 1-x Nd x ) 1-y Sm y Co 5 ±0.2, wherein 0.05 ≦ x ≦ 0.10 and 0 ≦ y ≦ 0.25 and CeMM is a cerium misch-metal of the formula Ce.sub.α La.sub.β Nd.sub.γ Pr.sub.δ, wherein 0.45 < α < 0.55 0.20 < β < 0.40 0.05 < γ < 0.15 0.00 < δ < 0.05 and α+ β +γ + δ ≃ 1 wherein the quantities of Nd added are within the range at which the coercive field strength is increased and less than the quantity at which the coercive field strength deteriorates.

Claim 8

A magnetic material of the formula (CeMM 1-x Nd x ) 1-y Sm y Co 5 ±0.2, wherein 0.05 ≦ x ≦ 0.10 and 0 ≦ y ≦ 0.25 and CeMM is a cerium misch-metal of the formula Ce.sub.α La.sub.β Nd.sub.γ Pr.sub.δ, wherein 0.45 < α < 0.55 0.20 < β < 0.40 0.05 < γ < 0.15 0.00 < δ < 0.05 and α+ β +γ + δ ≃ 1 wherein the quantities of Nd added are within the range at which the coercive field strength is increased and less than the quantity at which the coercive field strength deteriorates.

Claim 9

The magnetic material of claim 5, wherein α, β, γ, and δ are approximately 0.54, 0.30, 0.12 and 0.04, respectively.

Claim 10

A magnetic material of the formula (CeMM 1-x Pr x ) 1-y Sm y Co 5 ±0.2, wherein 0.03 < x < 0.06 and 0 ≦ y ≦ 0.25 and CeMM is a cerium misch-metal of the formula Ce.sub.α La.sub.β Nd.sub.γ Pr.sub.δ, wherein 0.45 < α < 0.55 0.20 < β < 0.40 0.05 < γ < 0.15 0.00 < δ < 0.05 and α + β + γ + δ ≃ 1 wherein the quantities of Pr added are within the range at which the coercive field strength is increased and less than the quantity at which the coercive field strength deteriorates.

Claim 11

A magnetic material of the formula (CeMM 1-x Pr x ) 1-y Sm y Co 5 ±0.2, wherein 0.03 < x < 0.06 and 0 ≦ y ≦ 0.25 and CeMM is a cerium misch-metal of the formula Ce.sub.α La.sub.β Nd.sub.γ Pr.sub.δ, wherein 0.45 < α < 0.55 0.20 < β < 0.40 0.05 < γ < 0.15 0.00 < δ < 0.05 and α + β + γ + δ ≃ 1 wherein the quantities of Pr added are within the range at which the coercive field strength is increased and less than the quantity at which the coercive field strength deteriorates.

Claim 12

The magnetic material of claim 7, wherein α, β, γ, and δ are approximately 0.54, 0.30, 0.12 and 0.04, respectively.

Claim 13

A process for the production of a permanent magnetic material of the formula: (CeMM 1-x RE x ) 1-y Sm y Co 5 ±0.2, wherein 0 ≦ y ≦ 0.25; wherein when RE is Ce, 0.05 < x < 0.25; when RE is La, 0.15 < x < 0.50; when RE is Nd, 0.05 < x < 0.10; and when RE is Pr, 0.03 < x < 0.06; and wherein Re is a rare earth selected from the group consisting of cerium, lanthanum, neodymium and praeodymium, and CeMM is a cerium misch-metal of the formula Ce.sub.α La.sub.β Nd.sub.γ Pr.sub.δ, wherein 0.45 < α < 0.55 0.20 < β < 0.40 0.05 < γ < 0.15 0.00 < δ < 0.05 and 60 + β + γ +δ ≃ 1, which consists essentially of introducing the starting alloy into a mill in coarsely disintegrated form; grinding it under a protective gas atmosphere to a powder of a particle size of 1 to 10 μm; admixing the powder formed in a magnetic field; isostatically compressing the resultant powder in to a pressed body; sintering the resultant powder between 1035° C and 1045° C and heat-treating the resultant sintered powder above 300° C.

Claim 14

A process for the production of a permanent magnetic material of the formula: (CeMM 1-x RE x ) 1-y Sm y Co 5 ±0.2, wherein 0 ≦ y ≦ 0.25; wherein when RE is Ce, 0.05 < x < 0.25; when RE is La, 0.15 < x < 0.50; when RE is Nd, 0.05 < x < 0.10; and when RE is Pr, 0.03 < x < 0.06; and wherein Re is a rare earth selected from the group consisting of cerium, lanthanum, neodymium and praeodymium, and CeMM is a cerium misch-metal of the formula Ce.sub.α La.sub.β Nd.sub.γ Pr.sub.δ, wherein 0.45 < α < 0.55 0.20 < β < 0.40 0.05 < γ < 0.15 0.00 < δ < 0.05 and 60 + β + γ +δ ≃ 1, which consists essentially of introducing the starting alloy into a mill in coarsely disintegrated form; grinding it under a protective gas atmosphere to a powder of a particle size of 1 to 10 μm; admixing the powder formed in a magnetic field; isostatically compressing the resultant powder in to a pressed body; sintering the resultant powder between 1035° C and 1045° C and heat-treating the resultant sintered powder above 300° C.

Claim 15

The process of claim 9, wherein the permanent magnetic material is annealed between 950° C and 1020° C for up to 50 hours.

Claim 16

The process of claim 9, wherein the permanent magnetic material is annealed at 980° ± 10° C for at least 6 hours.

Claim 17

The process of claim 9, wherein the permanent magnetic material is cooled in a liquid of silicone oil, glycerin or liquid nitrogen, or in a protective gas atmosphere of argon or nitrogen.

Claim 18

The process of claim 9, wherein the alloy is tempered between 300° C and 600° C for up to 60 minutes.

Claim 19

The process of claim 10, wherein the alloy, after tempering, is passed into a zone of lower temperature of about 300° C, and cooled to room temperature after a period of up to 1 hour.

Claim 20

The process of claim 9, wherein the starting alloy is fused from CeMMCo.sub. 5 and RECo 5 alloys, wherein RE is Ce, La, Nd or Pr.

Claim 21

The process of claim 9, wherein the starting alloy consists of mixed and disintegrated CeMMCo.sub. 5 and RECo 5 alloys, wherein Re is Ce, La, Nd, or Pr.

Claim 22

The process of claim 9, wherein the starting alloy, after mixing, is ground with a sintering additive.

Claim 23

The process of claim 9, wherein the sintering additive is an alloy containing 50 to 70 % Re and 35 to 50 % Co, wherein Re is Sn, Ce, La, Pr or Nd.

Claim 24

The process of claim 13, wherein the alloy is tempered at approximately 350° C for 30 to 40 minutes.

Claim 25

The process of claim 9, wherein said magnetic field is approximately 50 KOe.