High coercivity rare earth-iron magnets

Claim 1

A method of making an alloy with permanent magnetic properties at room temperature comprising the steps of forming a mixture of iron and one or more rare earth elements; heating said mixture to form a homogeneous molten alloy; and quenching said molten alloy at a rate such that it solidifies substantially instantaneously to form an alloy having an inherent room temperature magnetic coercivity of at least about 5,000 Oersteds as quenched.

Claim 2

A method of making an alloy with permanent magnetic properties at room temperature comprising the steps of forming a mixture of iron and one or more rare earth elements; heating said mixture to form a homogeneous molten alloy; and quenching said molten alloy at a rate such that it solidifies substantially instantaneously to form an alloy having an inherent room temperature magnetic coercivity of at least about 5,000 Oersteds as quenched.

Claim 3

A method of making a permanent magnet comprising the steps of: melting an alloy of 20 to 70 atomic percent iron and the balance one or more rare earth elements taken from the group consisting of praseodymium, neodymium, and samarium; quenching said molten alloy at a rate such that it solidifies substantially instantaneously to form an alloy with a substantially amorphous to very finely crystalline microstructure as measured by X-ray diffraction having a room temperature intrinsic magnetic coercivity of at least about 1,000 Oersteds; and comminuting and compacting said alloy into a magnet shape and magnetizing it in an applied magnetic field.

Claim 4

A method of making a permanent magnet comprising the steps of: melting an alloy of 20 to 70 atomic percent iron and the balance one or more rare earth elements taken from the group consisting of praseodymium, neodymium, and samarium; quenching said molten alloy at a rate such that it solidifies substantially instantaneously to form an alloy with a substantially amorphous to very finely crystalline microstructure as measured by X-ray diffraction having a room temperature intrinsic magnetic coercivity of at least about 1,000 Oersteds; and comminuting and compacting said alloy into a magnet shape and magnetizing it in an applied magnetic field.

Claim 5

A method of making an alloy with permanent magnetic properties comprising the steps of: alloying a mixture consisting essentially of 20 to 70 atomic percent iron and the balance of one or more rare earth elements taken from the group consisting of praseodymium, neodymium, and samarium; melting said alloy to form a fluid mass; withdrawing a small amount of said alloy from said fluid mass; and instantaneously quenching said small fluid amount such that the as quenched alloy has an inherent intrinsic magnetic coercivity of at least 1,000 Oersteds at room temperature.

Claim 6

A method of making an alloy with permanent magnetic properties comprising the steps of: alloying a mixture consisting essentially of 20 to 70 atomic percent iron and the balance of one or more rare earth elements taken from the group consisting of praseodymium, neodymium, and samarium; melting said alloy to form a fluid mass; withdrawing a small amount of said alloy from said fluid mass; and instantaneously quenching said small fluid amount such that the as quenched alloy has an inherent intrinsic magnetic coercivity of at least 1,000 Oersteds at room temperature.

Claim 7

A method of making a magnetically hard alloy directly from a molten mixture or iron and rare earth elements comprising: melting a mixture consisting essentially of 20 to 70 atomic percent iron and the balance one or more rare earth elements taken from the group consisting of neodymium, praseodymium, and mischmetals thereof; expressing said molten mixture from an orifice; and immmediately impinging said expressed mixture onto a chill surface moving at a rate with respect to the expressed metal such that it rapidly solidifies to form an alloy ribbon with a thickness less than about 200 microns having a magnetic coercivity at room temperature of at least about 1,000 Oersteds.

Claim 8

A method of making a magnetically hard alloy directly from a molten mixture or iron and rare earth elements comprising: melting a mixture consisting essentially of 20 to 70 atomic percent iron and the balance one or more rare earth elements taken from the group consisting of neodymium, praseodymium, and mischmetals thereof; expressing said molten mixture from an orifice; and immmediately impinging said expressed mixture onto a chill surface moving at a rate with respect to the expressed metal such that it rapidly solidifies to form an alloy ribbon with a thickness less than about 200 microns having a magnetic coercivity at room temperature of at least about 1,000 Oersteds.

Claim 9

A method of making an iron-rare earth element alloy having a magnetic coercivity of at least 1,000 Oersteds at room temperature comprising melting an alloy of 20 to 70 atomic percent iron and the balance one or more rare earth elements taken from the group consisting of praseodymium, neodymium, samarium, and mischmetals thereof; and ejecting said alloy through an orifice sized such that when the ejected alloy is impinged onto a chill surface traveling at a substantially constant velocity relative thereto, a ribbon having a thickness less than about 200 microns and a substantially amorphous to very finely crystalline microstructure as determinable by ordinary X-ray diffraction is formed.

Claim 10

A method of making an iron-rare earth element alloy having a magnetic coercivity of at least 1,000 Oersteds at room temperature comprising melting an alloy of 20 to 70 atomic percent iron and the balance one or more rare earth elements taken from the group consisting of praseodymium, neodymium, samarium, and mischmetals thereof; and ejecting said alloy through an orifice sized such that when the ejected alloy is impinged onto a chill surface traveling at a substantially constant velocity relative thereto, a ribbon having a thickness less than about 200 microns and a substantially amorphous to very finely crystalline microstructure as determinable by ordinary X-ray diffraction is formed.

Claim 11

A method of making an iron-rare earth element permanent magnet alloy having a Curie temperature above 295° K. and a coercivity greater than about 1,000 Oersteds at room temperature comprising melting an alloy consisting essentially of 20 to 70 atomic percent iron and the balance one or more rare earth elements taken from the group consisting of praseodymium, neodymium and samarium; expressing said alloy through an orifice; and impinging the expressed metal onto a chill surface traveling at a velocity relative thereto such that an alloy ribbon having a thickness less than about 200 microns is formed.

Claim 12

A method of making an iron-rare earth element permanent magnet alloy having a Curie temperature above 295° K. and a coercivity greater than about 1,000 Oersteds at room temperature comprising melting an alloy consisting essentially of 20 to 70 atomic percent iron and the balance one or more rare earth elements taken from the group consisting of praseodymium, neodymium and samarium; expressing said alloy through an orifice; and impinging the expressed metal onto a chill surface traveling at a velocity relative thereto such that an alloy ribbon having a thickness less than about 200 microns is formed.

Claim 15

A method of making an alloy with permanent magnetic properties at room and elevated temperatures comprising the steps of: mixing iron and one or more rare earth elements taken from the group consisting of praseodymium, neodymium and samarium; melting said mixture; and quenching said molten mixture at a rate such that it solidifies to form an alloy having a substantially flat X-ray diffraction pattern and an intrinsic magnetic coercivity at room temperature of at least about 1,000 Oersteds.

Claim 16

A method of making an alloy with permanent magnetic properties at room and elevated temperatures comprising the steps of: mixing iron and one or more rare earth elements taken from the group consisting of praseodymium, neodymium and samarium; melting said mixture; and quenching said molten mixture at a rate such that it solidifies to form an alloy having a substantially flat X-ray diffraction pattern and an intrinsic magnetic coercivity at room temperature of at least about 1,000 Oersteds.

Claim 17

A method of making an alloy with permanent magnetic properties at room temperature comprising the steps of: forming a mixture of iron and at least one rare earth element taken from the group consisting of praseodymium, neodymium, samarium and mischmetals thereof; heating said mixture in a crucible to form a homogeneous molten alloy; pressurizing said crucible to eject said mixture through an orifice in its bottom about 250-1200 micronmeters in diameter; and impinging said ejected mixture onto the perimeter of a chill wheel rotating at a rate such that an alloy ribbon less than 200 microns thick with an intrinsic coercivity of at least 5,000 Oersteds at room temperature is formed.

Claim 18

A method of making an alloy with permanent magnetic properties at room temperature comprising the steps of: forming a mixture of iron and at least one rare earth element taken from the group consisting of praseodymium, neodymium, samarium and mischmetals thereof; heating said mixture in a crucible to form a homogeneous molten alloy; pressurizing said crucible to eject said mixture through an orifice in its bottom about 250-1200 micronmeters in diameter; and impinging said ejected mixture onto the perimeter of a chill wheel rotating at a rate such that an alloy ribbon less than 200 microns thick with an intrinsic coercivity of at least 5,000 Oersteds at room temperature is formed.

Claim 19

A method of making an alloy which may be directly manufactured into a permanent magnet as it is quenched from the melt comprising: melting an alloy of iron and one or more rare earth elements taken from the group consisting of neodymium, praseodymium, samarium and mischmetals thereof; expressing said molten alloy from an orifice; and immediately impinging said expressed alloy onto a chill surface moving at a rate with respect to the expressed metal such that it solidifies substantially instantaneously to form a brittle ribbon with a thickness less than about 200 microns and a magnetic coercivity at room temperature of at least about 1,000 Oersteds.

Claim 20

A method of making an alloy which may be directly manufactured into a permanent magnet as it is quenched from the melt comprising: melting an alloy of iron and one or more rare earth elements taken from the group consisting of neodymium, praseodymium, samarium and mischmetals thereof; expressing said molten alloy from an orifice; and immediately impinging said expressed alloy onto a chill surface moving at a rate with respect to the expressed metal such that it solidifies substantially instantaneously to form a brittle ribbon with a thickness less than about 200 microns and a magnetic coercivity at room temperature of at least about 1,000 Oersteds.

Claim 21

A method of making an iron-rare earth element alloy having an inherent magnetic coercivity of at least 1,000 Oersteds at room temperature comprising: alloying a mixture of iron and one or more rare earth elements taken from the group consisting of praseodymium, neodymium, samarium and mischmetals thereof; melting said iron-rare earth alloy in a crucible having an outlet orifice through which said alloy may be expressed at a controlled rate; expressing said alloy from said orifice and impinging the expressed molten stream onto the perimeter of a rotating chill surface traveling at a relative velocity with respect to the stream such that an alloy ribbon having a thickness less than about 200 microns and a substantially amorphous to very finely crystalline microstructure as determinable by X-ray diffraction is formed.

Claim 22

A method of making an iron-rare earth element alloy having an inherent magnetic coercivity of at least 1,000 Oersteds at room temperature comprising: alloying a mixture of iron and one or more rare earth elements taken from the group consisting of praseodymium, neodymium, samarium and mischmetals thereof; melting said iron-rare earth alloy in a crucible having an outlet orifice through which said alloy may be expressed at a controlled rate; expressing said alloy from said orifice and impinging the expressed molten stream onto the perimeter of a rotating chill surface traveling at a relative velocity with respect to the stream such that an alloy ribbon having a thickness less than about 200 microns and a substantially amorphous to very finely crystalline microstructure as determinable by X-ray diffraction is formed.