Metal treatment – Stock – Magnetic
Reexamination Certificate
1997-12-31
2001-12-25
Sheehan, John (Department: 1742)
Metal treatment
Stock
Magnetic
C148S101000, C148S121000, C252S062540
Reexamination Certificate
active
06332933
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to magnetic materials, and more particularly relates to magnetic nanocomposite materials including iron, rare earth elements, boron and refractory metals which have favorable magnetic properties and are suitable for making bonded magnets.
BACKGROUND INFORMATION
Magnetic alloys containing neodymium, iron and boron have been widely studied for use in sintered and bonded magnets due to their favorable magnetic properties. The Nd
2
Fe
14
B phase has been identified as a hard magnetic phase exhibiting particularly good magnetic properties.
U.S. Pat. Nos. 4,402,770, 4,409,043 and Re. 34,322 to Koon, which are incorporated herein by reference, disclose magnetic alloys comprising lanthanum and other rare earth elements, transition metals such as iron and cobalt, and boron within specified ranges. Although the disclosed alloys have been found to possess good magnetic properties, such alloys do not have optimal properties, and have not become commercially viable.
The present invention has been developed in view of the foregoing and to address other deficiencies of the prior art.
SUMMARY OF THE INVENTION
The present invention provides a nanocomposite magnetic material of controlled composition which exhibits improved magnetic properties and can be easily processed.
An object of the present invention is to provide a nanocomposite magnetic material comprising Fe, rare earth elements, B, refractory metals and, optionally, Co within specified ranges.
Another object of the present invention is to provide a nanocomposite magnetic material of the formula: (Nd
1−y
La
y
)
v
Fe
100−v−w−x−z
Co
w
M
z
B
x
, where M is 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 from 0 to about 40; 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.
A further object of the present invention is to provide a nanocomposite magnetic material including a hard magnetic phase, a soft magnetic phase, and a refractory metal boride precipitated phase. The hard magnetic phase is preferably Nd
2
Fe
14
B, while the soft magnetic phase preferably comprises &agr;-Fe, Fe
3
B or a combination thereof.
Another object of the present invention is to provide a method of making a nanocomposite magnetic material. The method includes the steps of providing a molten composition comprising Fe, rare earth elements, B, at least one refractory metal and, optionally, Co, rapidly solidifying the composition to form a substantially amorphous material, and thermally treating the material to form crystalline magnetic phases of desired composition and size.
These and other objects of the present invention will become more apparent from the following description.
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Bauer et al.,
Bounds Charles O.
Chang Wen Cheng
Chen Qun
Ma Bao-Min
Santoku Corporation
Sheehan John
Stevens Davis Miller & Mosher LLP
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