Additive manufacture of anisotropic rare earth magnets

Patent metadata

Field	Value
Publication number	US-11920224-B2
Application number	US-202217572193-A
Country	US
Kind code	B2
Filing date	Jan 10, 2022
Priority date	Sep 24, 2018
Publication date	Mar 5, 2024
Grant date	Mar 5, 2024

Abstract

A magnet structure includes columnar grains of rare earth permanent magnet phase aligned in a same direction and arranged to form bulk anisotropic rare earth alloy magnet having a boundary defined by opposite ends of the columnar grains and lacking triple junction regions, and rare earth alloy diffused onto opposite ends of the bulk anisotropic rare earth alloy magnet.

First claim

What is claimed is:

1. A magnet structure comprising:
columnar grains of rare earth permanent magnet phase aligned in a same direction and arranged to form a bulk anisotropic rare earth alloy magnet (i) having an outer surface boundary defined by opposite ends of the columnar grains and (ii) completely lacking triple junction regions; and
rare earth alloy diffused onto the outer surface boundary.

2. The magnet structure of claim 1 , wherein the rare earth permanent magnet phase is RE-Fe-B.

3. The magnet structure of claim 1 , wherein the rare earth permanent magnet phase includes Ce, Dy, La, Pr, or Tb.

Assignees

• Ford Global Tech Llc

Inventors

• Li Wanfeng
• Liang Feng
• Degner Michael W

Classifications

• C22C33/0207 Primary

  Using a mixture of pre-alloyed powders or a master alloy · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22F10/38

  to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures · CPC title

• H01F1/053

  containing rare earth metals · CPC title

• H01F7/02

  Permanent magnets {[PM]} · CPC title