Method and particle mixture for making rare earth element, iron and boron permanent sintered magnets

Claim 1

A method for producing sintered permanent magnets of a permanent magnet alloy comprising a rare earth element, iron and boron, said method comprising providing permanent magnet, rare earth element, iron and boron alloy material selected from one of: a) dross alloy and up to 6% scrap alloy; b) dross alloy and virgin alloy; and c) dross alloy and virgin alloy and greater than 0 to 80% scrap alloy, sequentially hydriding said material in a hydrogen atmosphere to hydride and decreptitate said material to form particles therefrom, reducing the size of said particles, compacting said particles and dehydriding and sintering the particles to produce a substantially fully dense article for use as a permanent magnet.

Claim 2

A method for producing sintered permanent magnets of a permanent magnet alloy comprising a rare earth element, iron and boron, said method comprising providing permanent magnet, rare earth element, iron and boron alloy material selected from one of: a) dross alloy and up to 6% scrap alloy; b) dross alloy and virgin alloy; and c) dross alloy and virgin alloy and greater than 0 to 80% scrap alloy, sequentially hydriding said material in a hydrogen atmosphere to hydride and decreptitate said material to form particles therefrom, reducing the size of said particles, compacting said particles and dehydriding and sintering the particles to produce a substantially fully dense article for use as a permanent magnet.

Claim 3

A method for producing sintered permanent magnets of a permanent magnet alloy comprising a rare earth element, iron and boron, said method comprising sequentially subjecting dross of said alloy to a hydrogen atmosphere to hydride and decrepitate said dross to form particles therefrom, reducing the size of said particles, compacting said particles and dehydriding and sintering the particles to produce a substantially fully dense article for use as a permanent magnet.

Claim 4

A method for producing sintered permanent magnets of a permanent magnet alloy comprising a rare earth element, iron and boron, said method comprising sequentially subjecting dross of said alloy to a hydrogen atmosphere to hydride and decrepitate said dross to form particles therefrom, reducing the size of said particles, compacting said particles and dehydriding and sintering the particles to produce a substantially fully dense article for use as a permanent magnet.

Claim 5

A method for producing sintered permanent magnets of a permanent magnet alloy comprising a rare earth element, iron and boron, said method comprising subjecting dross of said alloy to a hydrogen atmosphere to hydride and decrepitate said dross to form first particles, subjecting rare earth element, iron and borin virgin alloy to a hydrogen atmosphere to hydride and decrepitate said virgin alloy to form second particles, reducing the size of said first and second particles, blending said first and second particles to produce a particle mixture, sequentially compacting said particle mixture and dehydriding and sintering the particle mixture to produce a substantially fully dense article for use as a permanent magnet.

Claim 6

A method for producing sintered permanent magnets of a permanent magnet alloy comprising a rare earth element, iron and boron, said method comprising subjecting dross of said alloy to a hydrogen atmosphere to hydride and decrepitate said dross to form first particles, subjecting rare earth element, iron and borin virgin alloy to a hydrogen atmosphere to hydride and decrepitate said virgin alloy to form second particles, reducing the size of said first and second particles, blending said first and second particles to produce a particle mixture, sequentially compacting said particle mixture and dehydriding and sintering the particle mixture to produce a substantially fully dense article for use as a permanent magnet.

Claim 7

A method for producing sintered permanent magnets of a permanent magnet alloy comprising a rare earth element, iron and boron, said method comprising subjecting scrap of said alloy to a hydrogen atmosphere to hydride and decrepitate said scrap to form first particles, subjecting dross of said alloy to a hydrogen atmosphere to hydride and decrepitate said dross to form second particles, reducing the size of said first and second particles, blending said first and second particles to produce a particle mixture of up to 60% first particles and balance second particles, and sequentially compacting said particle mixture and dehydriding and sintering the particle mixture to produce a substantially fully dense article for use as a permanent magnet.

Claim 8

A method for producing sintered permanent magnets of a permanent magnet alloy comprising a rare earth element, iron and boron, said method comprising subjecting scrap of said alloy to a hydrogen atmosphere to hydride and decrepitate said scrap to form first particles, subjecting dross of said alloy to a hydrogen atmosphere to hydride and decrepitate said dross to form second particles, reducing the size of said first and second particles, blending said first and second particles to produce a particle mixture of up to 60% first particles and balance second particles, and sequentially compacting said particle mixture and dehydriding and sintering the particle mixture to produce a substantially fully dense article for use as a permanent magnet.

Claim 9

A method for producing sintered permanent magnets of a permanent magnet alloy comprising a rare earth element, iron and boron, said method comprising subjecting scrap of said alloy to a hydrogen atmosphere to hydride and decrepitate said scrap to form first particles, subjecting dross of said alloy to a hydrogen atmosphere to hydride and decrepitate said dross to form second particles, subjecting rare earth element, iron and boron virgin alloy to a hydrogen atmosphere to hydride and decrepitate said virgin alloy to form third particles, reducing the size of said first, second and third particles, blending said first, second and third particles to produce a particle mixture of up to 80% first particles and balance second and third particles, and sequentially compacting said particle mixture and dehydriding and sintering the particle mixture to produce a substantially fully dense article for use as a permanent magnet.

Claim 10

A method for producing sintered permanent magnets of a permanent magnet alloy comprising a rare earth element, iron and boron, said method comprising subjecting scrap of said alloy to a hydrogen atmosphere to hydride and decrepitate said scrap to form first particles, subjecting dross of said alloy to a hydrogen atmosphere to hydride and decrepitate said dross to form second particles, subjecting rare earth element, iron and boron virgin alloy to a hydrogen atmosphere to hydride and decrepitate said virgin alloy to form third particles, reducing the size of said first, second and third particles, blending said first, second and third particles to produce a particle mixture of up to 80% first particles and balance second and third particles, and sequentially compacting said particle mixture and dehydriding and sintering the particle mixture to produce a substantially fully dense article for use as a permanent magnet.

Claim 11

The method of claims 1 or 2 or 3 or 4 or 5 wherein the size of said particles is reduced by jet milling.

Claim 15

The method of claims 1 or 2 or 3 or 4 or 5 wherein the hydrogen atmosphere is at a pressure of 1 to 400 psi for 2 to 4 hours.

Claim 17

The method of claims 1 or 2 or 3 or 4 or 11 wherein said article is heat treated at a temperature of 550°-650° for 1 to 3 hours in an inert atmosphere or vacuum and is then quenched.