Permanent magnet including multiple ferromagnetic phases and method for producing the magnet

1. A method for producing an iron-based rare earth alloy nanocomposite magnet including a hard magnetic phase and a soft magnetic phase, comprising the steps of:

preparing a melt of a material alloy, the material alloy having a composition represented by the general formula: (Fe 1-m T m ) 100-x-y-z Q x R y M z , where T is at least one element selected from the group consisting of Co and Ni; Q is at least one element selected from the group consisting of B and C; R is at least one rare earth element substantially excluding La and Ce; and M is at least one metal element selected from the group consisting of Ti, Zr and Hf and always includes Ti, the mole fractions x, y, z and m meeting the inequalities of:

10 at %<x≦20 at %;

6 at %≦y<10 at %;

0.1 at %≦z≦12 at %; and

0≦m≦0.5, respectively;

rapidly cooling the melt to make a rapidly solidified alloy comprising an R 2 Fe 14 B crystalline phase by:

bringing the melt into contact with the surface of a rotating chill roller to obtain a supercooled liquid alloy; and

dissipating heat from the supercooled alloy into the ambient gas to grow the R 2 Fe 14 B phase after the supercooled alloy has left the chill roller; and thermally treating the rapidly solidified alloy to form a structure in which two or more ferromagnetic crystalline phases, including the hard and the soft magnetic phases, exist, an average grain size of the hard magnetic phase is equal to or greater than 10 nm and equal to or less than 200 nm, and an average grain size of the soft magnetic phase is equal to or greater than 1 nm and equal to or less than 100 nm.

2. The method of claim 1 , wherein said rapidly solidified alloy made in the cooling step includes an R 2 Fe 14 B phase at 60 volume percent or more.

3. The method of claim 1 , wherein said cooling step comprises rapidly cooling the melt within an ambient gas at a pressure of 30 kPa or more to make a rapidly solidified alloy including an R 2 Fe 14 B phase with an average grain size of 50 nm or less.

4. The method of claim 1 , comprising the step of forming a structure in which three or more crystalline phases, including at least R 2 Fe 14 B compound, α-Fe and boride phases are included an average crystal grain size of the R 2 Fe 14 B phase is between 20 nm and 150 nm, and an average crystal grain size of the α-Fe and boride phases is between 1 nm and 50 nm.

5. The method of claim 4 , wherein said steps of heating and crystallizing the rapidly solidified alloy produces a boride phase comprising an iron-based boride with ferromagnetic properties.

6. The method of claim 5 , wherein said steps of heating and crystallizing the rapidly solidified alloy produces a boride phase comprising an iron-based boride comprises Fe 3 B and/or Fe 23 B 6 .

7. The method of claim 1 , wherein said step of cooling the melt is effected via a strip casting process.

8. A method for producing a bonded magnet, the method comprising the steps of:

preparing a powder of the iron-based rare earth alloy magnet by the method as recited in claim 1 ; and

processing the powder into a bonded magnet.