Method for Producing Carbide/Nitride Grain Refined Rare Earth-Iron-Boron Permanent Magnets

The document presents a method for producing carbide/nitride grain refined rare earth-iron-boron permanent magnets. This innovative approach focuses on the synthesis of a permanent magnet through a carefully controlled process. The method involves forming a melt with a specific base alloy composition, which includes rare earth elements (RE), iron (Fe), and boron (B). The introduction of transition metals (TR) such as titanium (Ti) and zirconium (Zr) enhances the properties of the final product. The significance of this method lies in its ability to create a thermodynamically stable compound, which is crucial for achieving optimal magnetic properties. The document emphasizes the importance of stoichiometric amounts of carbon (C) and nitrogen (N) in the alloy composition, which contribute to the formation of a hard magnetic phase.

The methodology outlined in the document is systematic and detailed. Initially, a melt is created with the specified alloy composition. The process requires rapid solidification to form particulates with an amorphous structure. This structure is essential for the subsequent heating phase, where the particulates are heated above their crystallization temperature. This step is critical as it allows for the nucleation and growth of a hard magnetic phase, which is necessary for the performance of the permanent magnet. The document highlights that the size of the grains must be optimized to enhance magnetic properties. The consolidation of crystallized particulates at elevated temperatures is another key aspect of the methodology. This step ensures that primary and secondary precipitates effectively pin the grain boundaries, minimizing harmful grain growth.

The results of the method demonstrate significant advancements in the production of permanent magnets. The formation of primary TRC, TRN, and TRC/N precipitates during the solidification process plays a vital role in enhancing the magnetic properties of the final product. The document discusses how these precipitates contribute to the stability and performance of the magnets. The analysis indicates that the method not only improves the magnetic properties but also offers a more efficient production process. The practical applications of these refined magnets are vast, ranging from electric motors to magnetic resonance imaging (MRI) systems. The ability to produce high-performance magnets with tailored properties opens new avenues for technological advancements in various fields.

In conclusion, the document provides a comprehensive overview of a method for producing carbide/nitride grain refined rare earth-iron-boron permanent magnets. The innovative approach detailed in the patent offers significant improvements in the synthesis and performance of permanent magnets. The emphasis on the alloy composition, rapid solidification, and controlled heating processes highlights the method's effectiveness. The findings underscore the potential for real-world applications, making this research valuable for industries reliant on high-performance magnetic materials. Future research may focus on optimizing the process further and exploring additional alloy compositions to enhance the properties of permanent magnets.