IRON-BASED RARE-EARTH-CONTAINING NANOCOMPOSITE MAGNET AND PROCESS FOR PRODUCING THE SAME

1 . An iron-based rare-earth nanocomposite magnet comprising an Nd 2 Fe 14 B phase and an α-Fe phase and having a composition represented by the compositional formula:

T 100-x-y-z-n (B 1-q C q ) x R y Ti z M n , where T is at least one transition metal element selected from the group consisting of Fe, Co and Ni and always including Fe, R is at least one rare-earth element including substantially no La or Ce, and M is at least one metal element selected from the group consisting of Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb, and the mole fractions x, y, z, n and q satisfy the inequalities of:

4 at %≦x≦10 at %,

6 at %≦y≦10 at %,

0.05 at %≦z≦5 at %,

0 at %≦n≦10 at %, and

0.05≦q≦0.5, respectively,

wherein the magnet includes 5 vol % to 60 vol % of α-Fe phase with an average crystal grain size of 1 nm to 50 nm and 40 vol % to 90 vol % of Nd 2 Fe 14 B phase with an average crystal grain size of 5 nm to 100 nm, and

wherein a non-magnetic phase including at least Ti and C (carbon) is present on the grain boundary between the α-Fe and Nd 2 Fe 14 B phases.

2 . The iron-based rare-earth nanocomposite magnet of claim 1 , wherein the α-Fe phase with the average crystal grain size of 1 nm to 50 nm has a crystal grain size standard deviation of 10 nm or less and the Nd 2 Fe 14 B phase with the average crystal grain size of 5 nm to 100 nm has a crystal grain size standard deviation of 15 nm or less.

3 . The iron-based rare-earth nanocomposite magnet of claim 1 , wherein the magnet exhibits permanent magnet properties including a remanence B r of 0.9 T or more, a maximum energy product (BH) max of 120 kJ/m 3 or more, and a coercivity H cJ of 400 kA/m or more.

4 . A method for producing an iron-based rare-earth nanocomposite magnet that includes an Nd 2 Fe 14 B phase and an α-Fe phase, the method comprising the steps of:

preparing a melt of an alloy that has a composition represented by the compositional formula:

T 100-x-y-z-n (B 1-q C q ) x R y Ti z M n , where T is at least one transition metal element selected from the group consisting of Fe, Co and Ni and always including Fe, R is at least one rare-earth element including substantially no La or Ce, and M is at least one metal element selected from the group consisting of Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb, and the mole fractions x, y, z, n and q satisfy the inequalities of:

4 at %≦x≦10 at %,

6 at %≦y≦10 at %,

0.05 at %≦z≦5 at %,

0 at %≦n≦10 at %, and

0.05≦q≦0.5, respectively; and

quenching the melt at a quenching rate of 5×10 3 ° C./s to 5×10 7 ° C./s, thereby making a rapidly solidified alloy, which includes at least 10% of crystalline phases including the Nd 2 Fe 14 B phase and the α-Fe phase and having an average crystal grain size of 100 nm or less and an amorphous phase as the balance.

5 . The method of claim 4 , further comprising the step of thermally treating and crystallizing the rapidly solidified alloy by heating the alloy to a temperature of 500° C. to 800° C. at a rate of 0.5° C./s to 7° C./s after the step of quenching the melt has been performed.

6 . The method of claim 4 , further comprising the step of pulverizing the rapidly solidified alloy after the step of quenching the melt has been performed.

7 . The method of claim 4 , wherein the alloy satisfies 8 at %≦y≦10 at %.

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

preparing a magnet powder by the method of claim 6 ; and

adding a resin binder to the magnet powder and molding the powder and the binder.