Preparation of hard magnetic alloys of a transition metal and lanthanide

Abstract

A method of preparing alloy of a transition metal and lanthanide comprising the steps of alloying a transition metal, boron, at least one lower-weight lanthanide having none or few stable compounds with iron, optionally one or more higher-weight lanthanides, a glass former, and optionally the pseudo lanthanide, yttrium; forming an amorphous or nearly amorphous metastable microstructure in the alloy; and heating the amorphous alloy to form a polycrystalline, multiphase, fine-grain single-domain structure.

What is claimed and desired to be secured by Letters Patent of the United States is: 
     
       1. A method of preparing a hard magnetic polycrystalline alloy which comprise the steps of preparing an alloy represented by the formula: .[.   (M.sub.w X.sub.x B.sub.1-w-x).sub.1-y (Y.sub.v RL.sub.1-v-z).sub.y       (.Iadd.M.sub.w X.sub.x B.sub.1-w-x).sub.1-y (Y.sub.v R'.sub.z L.sub.1-v-z).sub.y .Iaddend.     wherein v is from 0 to 0.8, w is from about 0.7 to about 0.98; x is from 0 to about 0.15; y is from about 0.05 to about 0.25; z z is from 0 to about 0.95; M is selected from the .[.class.]. .Iadd.group .Iaddend.consisting of iron, cobalt, an iron-cobalt alloy, an iron-manganese alloy having at least 50 atomic percent iron, an iron-cobalt-manganese alloy having at least 50 atomic percent iron and cobalt, X is an .[.auxillary.]. auxiliary glass former selected from the .[.class.]. .Iadd.group .Iaddend.consisting of phosphorous, silicon, aluminum, arsenic, .[.genmanium.]. .Iadd.germanium.Iaddend., .[.indinum.]. .Iadd.indium.Iaddend., antimony, bismuth, tin and mixtures thereof, R' is a heavier-weight lanthanide .Iadd.selected from the group consisting of europium and lanthanides having heavier than europium and L is a lighter weight lanthanide .Iadd.selected from the group consisting of cerium, praseodymium, neodymium.]..Iaddend. .Iadd.samarium.Iaddend., said alloy having a polycrystalline, multiphase, single-domain microstructure wherein the average crystal-grain size does not exceed 400 .[.A.]. .Iadd.Å.Iaddend.;   creating an amorphous microstructure in said alloy; .Iadd.and .Iaddend.   heating said alloy at a temperature from about 850 to 1200 K. in a magnetic field of at least one kOe until a polycrystalline microstructure is obtained.   
     
     
       2. The method of claim 1 wherein said temperature is from 950 to 1025 K. and the magnetic field is at least 15 kOe. 
     
     
       3. The method of claim 1 wherein said amorphous alloy is heated at a temperature from about 1100 to 1200 K. for a period of time from about 15 to 120 seconds. 
     
     
       4. The method of claim 2 wherein M is iron and x is zero. 
     
     
       5. The method of claim 4 wherein R' is selected from the .[.class.]. .Iadd.group .Iaddend.consisting of terbium, dysprosium, holmium, and erbium. 
     
     
       6. The method of claim 5 wherein z is from 0.4 to 0.75. 
     
     
       7. The method of claim 5 wherein L, R', and yttrium are selected along with the amounts thereof so that the molecular volume thereof is from 20.7 to 21.0 cc/mole. 
     
     
       8. The method of claim 6 wherein L, R', and yttrium are selected along with the amount thereof so that the molecular volume thereof is from 20.7 to 21.0 cc/mole. 
     
     
       9. The method of claim 7 wherein the molecular volume is 20.8 to 20.95 cc/mole. 
     
     
       10. The method of claim 8 wherein the molecular volume is 20.8 to 20.95 cc/mole. 
     
     
       11. The method of claim 3 wherein M is iron and x is zero. 
     
     
       12. The method of claim 11 wherein R' is selected from the .[.class.]. .Iadd.group .Iaddend.consisting of terbium, dysprosium, holmium, and erbium. 
     
     
       13. The method of claim 12 wherein z is from 0.4 to 0.75. 
     
     
       14. The method of claim 12 wherein L, R', and yttrium are selected along with the amount thereof so that the molecular volume thereof is from 20.7 to 21.0 cc/mole. 
     
     
       15. The method of claim 13 wherein L, R', and yttrium are selected along with the amount thereof so that the molecular volume thereof is from 20.7 to 21.0 cc/mole. 
     
     
       16. The method of claim 14 wherein the molecular volume is 20.8 to 20.95 cc/mole. 
     
     
       17. The method of claim 13 wherein the molecular volume is 20.8 to 20.95 cc/mole. 
     
     
       18. The method of claim 2 wherein said magnetic field is at least 25 kOe. 
     
     
       19. The method of claim 3 wherein said magnetic field is at least 25 kOe. 
     
     
       20. The method of claim 4 wherein said magnetic field is at least 25 kOe. .Iadd. 
     
     
       21.  The method of claim 1 wherein z is 0 and L is selected from the group consisting of neodymium and praseodymium. .Iaddend. .Iadd.22. The method of claim 21 wherein L is neodymium. .Iaddend. .Iadd.23. The method of claim 21 wherein L is praseodymium. .Iaddend. .Iadd.24. The method of claim 21 wherein y is from 0.05 to 0.22. .Iaddend. .Iadd.25. The method of claim 21 wherein y is from 0.05 to 0.20. .Iaddend. .Iadd.26. A method of preparing a hard magnetic polycrystalline alloy which comprise the steps of preparing an alloy represented by the formula:   (M.sub.w X.sub.x B.sub.1-w-x).sub.-1-y (Y.sub.v R'.sub.z L.sub.1-v-z).sub.y     wherein v is from 0 to 0.8, w is from about 0.7 to about 0.98; x is from 0 to about 0.15; y is from about 0.05 to about 0.25; z is from 0 to about 0.95; M is selected from the class consisting of iron, cobalt, an iron-cobalt alloy, an iron-cobalt alloy, an iron-manganese alloy having at least 50 atomic percent iron, an iron-cobalt-manganese alloy having at least 50 atomic percent iron and cobalt, X is an auxiliary glass former selected from the class consisting of phosphorous, silicon, aluminum, arsenic, germanium, indium, antimony, bismuth, tin and mixtures thereof, R' is a heavier-weight lanthanide selected from the group consisting of europium and lanthanides heavier than europium and L is a mixture of lanthanum and an amount of a lighter weight lanthanide selected from the group consisting of praseodymium and neodymium effective to enhance the magnetic properties of said alloy, said alloy having a polycrystalline, multiphase, single-domain microstructure wherein the average crystal-grain size does not exceed 400Å;   creating an amorphous microstructure in said alloy; and   heating said alloy at a temperature from about 850 to 1200 K in a magnetic field of at least one kOe until a polycrystalline microstructure is obtained. .Iaddend.