Abstract
A process is described for producing elongated single-domain (ESD) fine-particle magnets. The 150-A. ESD iron or iron–cobalt alloy particles are prepared by controlled electrodeposition into mercury, followed by thermal growth and treatment with a third metal to attain optimum particle shape and magnetic properties. The particles are then aligned by a magnetic field, compacted under pressure, freed of mercury by vacuum distillation, and embedded in a suitable matrix. This is ground to a coarse powder and fed into automatic presses for realigning and compacting to the final magnet shape. The factors controlling each step of the process are discussed, and the advantages of magnets with artificial microstructures synthesized by this approach are pointed out. The process described produces commercial ESD iron and iron–cobalt magnets with energy products of 2·2 and 3·5 million gauss-oersteds, and laboratory ESD iron and iron–cobalt magnets of 4·2 and 5·0 million gauss-oersteds.
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