Alloy compositions comprising cerium and lanthanum, and magnetic powders and bonded magnets comprising them

Abstract

The present invention relates to alloy compositions comprising cerium and lanthanum with formula of Formula (I), (RE1 1-vRE2 v)yFe100-y-z-wZrwBz, wherein RE1 represents (Ce1-xLax); RE2 represents(Nd1-uPru); 0 ≤ v ≤ 0.1; 0 < x ≤ 0.5; 0 < u < 1; 10 ≤ y ≤ 20; 0 < w ≤ 5; and 4 ≤ z ≤ 8, wherein u, v, w, x, y, and z are atom%. The present invention also relates to magnetic powders comprising the alloy compositions as disclosed herein. The present invention further relates to bonded magnets comprising the magnetic powders as disclosed herein.

Description

[0001] Alloy Compositions Comprising Cerium and Lanthanum, and Magnetic Powders and Bonded Magnets Comprising Them

[0002] Technical Field

[0003] The present invention generally relates to alloy compositions, and more particularly to alloy compositions comprising Cerium and Lanthanum, and magnetic powders and bonded magnets comprising them.

[0004] Background Art

[0005] Bonded magnets, such as rare earth magnets, are used widely in various applications, including computer hardware, consumer electronics, automobiles, and household appliances. A common factor between these applications is that magnets are expected to work at high temperatures of above 100 °C while retaining their magnetic properties.

[0006] Neodymium magnets, known by their formula Nd-Fe-B, are permanent magnets that currently exhibit the highest magnetic properties, especially their maximum energy product ((BH)max). They are widely used in fields such as microwave communication, electrical engineering, and electroacoustic devices. However, neodymium, being a non-renewable rare earth metal, is becoming increasingly rare and expensive to use as a raw material.

[0007] Cerium has been proposed as a rare earth alternative to neodymium for use in magnets due to its abundance and lower price. However, it is well known that cerium -containing magnets exhibit deterioration of magnetic properties, especially when concentrations of Ce / TRE (Total Rare Earth) are higher than 30%. Furthermore, cerium-containing magnets exhibit decreased thermal stability at higher temperatures.

[0008] Ferrite has also been touted as a cheaper alternative to rare earth magnets. High-end grade ferrite magnets have magnetic properties close to those of low -end grades of Nd-Fe-B bonded magnets with high cerium concentrations. Ferrite magnets also retain relatively high intrinsic coercivity (HCi) at high temperatures and have a high resistance to demagnetisation. However, the use of ferrite in magnets also comes with drawbacks. For example, it is difficult to form a ring-shaped ferrite magnet for use in motor applications such as automotive accessory motors and fans as high-end ferrite magnets are magnetically anisotropic and require magnetic alignment to produce. Furthermore, it is also difficult to achieve high number of magnetic poles on a ferrite ring magnet due to complex alignment tools.

[0009] Thus, there is a need to find new alloy compositions for magnetic powders and bonded magnets that are made of abundant and cheap raw materials while possessing strong magnetic properties to ameliorate one or more problems stated above.

[0010] Summary

[0011] In an aspect of the present invention, there is provided an alloy composition of Formula (I): wherein:

[0012] RE' represents (Cei.xLax); RE2represents (Ndi-uPru);

[0013] 0 < v < 0.1;

[0014] 0 < x < 0.5;

[0015] 0 < u < 1 ;

[0016] 10 < y < 20;

[0017] 0 < w < 5 ; and

[0018] 4 < z < 8, wherein u, v, w, x, y, and z arc atom%.

[0019] In another aspect of the present invention, there is provided a magnetic powder comprising the alloy composition as disclosed herein.

[0020] In a further aspect of the present invention, there is provided a bonded magnet comprising the magnetic powder as disclosed herein.

[0021] Advantageously, the disclosed magnetic powders and bonded magnets may comprise mainly, and in most of the cases only, cerium and lanthanum as the rare earth (RE) component, which makes the disclosed magnetic powders and bonded magnets very low-cost and provides a new way to a more balanced use of RE resources in producing RE-Fe-B magnets. The cerium- and lanthanum- containing magnetic powders and bonded magnets of the present disclosure still advantageously exhibit strong magnetic properties.

[0022] Advantageously, the disclosed magnetic powders and bonded magnets may exhibit a very fine nanoscale grain size, which advantageously allows the disclosed magnetic powders and bonded magnets to exhibit higher remanence (Br) and max energy product (BH)maxvalues. This also advantageously allows the disclosed bonded magnets to exhibit improved compressibility and higher magnet densities.

[0023] Further advantageously, the disclosed magnetic powders may exhibit improved quench stability, resulting in more stable and repeatable magnetic properties in a broader processing range, and making it suitable for robust mass production.

[0024] Also advantageously, the disclosed magnetic powders and bonded magnets may exhibit improved magnetizing ability by requiring a lower magnetizing field strength for full magnetic saturation.

[0025] Further advantageously, the alloy compositions of the present disclosure are able to form magnets of various shapes, for example ring-shaped magnets, due to the magnetic powders comprising the alloy compositions being isotropic in nature, i.e. being magnetized in any particular direction. This is beneficial as magnets with a ring-shape are widely used in industries such as automotive, robotics, and aerospace industries where the ring shape provides improved efficiency and torque in applications such as DC motors due to their distinctive magnetic profile.

[0026] Definitions

[0027] The following are some definitions that may he helpful in understanding the description of the present invention. These are intended as general definitions and should in no way limit the scope of the present invention to those terms alone, but are put forth for a better understanding of the following description. The word “substantially’' does not exclude “completely” e.g. a composition which is “substantially free” from Y may be completely free from Y. Where necessary, the word “substantially” may be omitted from the definition of the invention.

[0028] Unless specified otherwise, the terms "comprising" and "comprise", and grammatical variants thereof, are intended to represent "open" or "inclusive" language such that they include recited elements but also permit inclusion of additional, unrecited elements.

[0029] As used herein, the term "about", in the context of concentrations of components of the formulations, typically means + / - 5% of the stated value, more typically + / - 4% of the stated value, more typically + / - 3% of the stated value, more typically, + / - 2% of the stated value, even more typically + / - 1% of the stated value, and even more typically + / - 0.5% of the stated value.

[0030] Throughout this disclosure, certain embodiments may be disclosed in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the disclosed ranges. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub -ranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed sub -ranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

[0031] Certain embodiments may also be described broadly and generically herein. Each of the narrower species and subgeneric groupings falling within the generic disclosure also form part of the disclosure. This includes the generic description of the embodiments with a proviso or negative limitation removing any subject matter from the genus, regardless of whether or not the excised material is specifically recited herein.

[0032] Brief Description of Drawings

[0033] The accompanying drawings illustrate disclosed embodiments and serve to explain the principles of the disclosed embodiments. It is to be understood, however, that the drawings are designed for purposes of illustration only, and not as a definition of the limits of the invention.

[0034] Fig. 1

[0035] Fig. 1 is an X-Ray Powder Diffraction (XRPD) spectrum comparing the X-ray diffraction pattern of the alloy compositions of Table 1 which have different amounts of La, Zr, Nd, and / or Pr.

[0036] Fig. 2

[0037] Fig. 2 is a graph comparing the effect of magnetizing field on the magnetization saturation of an embodiment of the present invention ((Ceo.sLaorjwsFeyg.sZrojBe.i) and a comparative embodiment (Ndi3.4Fego.3B5.8).

[0038] Fig. 3

[0039] Fig. 3 is a graph comparing the effect of the amount of Zr on the magnet compressibility of compression moulded (CM) magnets comprising the alloy compositions of some embodiments in Table 1. Fig. 4a

[0040] Fig. 4a is a graph showing the B-H curve and the B-H line of a bonded magnet of a comparative embodiment comprising Ce^eys.yZriBb.i.

[0041] Fig. 4b

[0042] Fig. 4b is a graph showing the B-H curve and the B-H line of a CM bonded magnet of the present invention comprising (Cen 9Lao i ) ,4Fe7s9Zri Bfii .

[0043] Fig. 4c

[0044] Fig. 4c is a graph showing the B-H curve and the B-H line of a CM bonded magnet of the present invention comprising (Ceo.gLao^luFevs sZriBe.i.

[0045] Fig. 4d

[0046] Fig. 4d is a graph showing the B-H curve and the B-H line of a bonded magnet of the present invention comprising (Ceo.7Lao3)i4Fe789ZriB6.i.

[0047] Fig. 4e

[0048] Fig. 4e is a graph showing the B-H curve and the B-H line of a bonded magnet of the present invention comprising (Ceo.8Lao2)i43Fe78.9Zro.7B6.i.

[0049] Fig. 4f

[0050] Fig. 4f is a graph showing the B-H curve and the B-H line of a bonded magnet of a comparative embodiment comprising (Cco.sLao ^isFcvs.gBe.i.

[0051] Detailed Disclosure of Embodiments

[0052] The present invention provides an alloy composition with Formula (I) : wherein:

[0053] In some embodiments, v in the alloy composition of Formula (1) may be in a range of at least 0, at least about 0.01, at least about 0.02, at least about 0.03, at least about 0.04, at least about 0.05, at least about 0.06, at least about 0.07, at least about 0.08, at least about 0.09, at least about 0.1 , or from 0 to about 0.1, from about 0.01 to about 0.1, from about 0.02 to about 0.1, from about 0.03 to about 0.1, from about 0.04 to about 0.1, from about 0.05 to about 0.1, from about 0.06 to about 0.1, from about 0.07 to about 0.1, from about 0.08 to about 0.1, from about 0.09 to about 0.1, from 0 to about 0.09, from about 0.01 to about 0.09, from about 0.02 to about 0.09, from about 0.03 to about 0.09, from about 0.04 to about 0.09, from about 0.05 to about 0.09, from about 0.06 to about 0.09, from about 0.07 to about 0.09, from about 0.08 to about 0.09, from 0 to about 0.08, from about 0.01 to about 0.08, from about 0.02 to about 0.08, from about 0.03 to about 0.08, from about 0.04 to about 0.08, from about 0.05 to about 0.08, from about 0.06 to about 0.08, from about 0.07 to about 0.08, from 0 to about 0.07, from about 0.01 to about 0.07, from about 0.02 to about 0.07, from about 0.03 to about 0.07, from about 0.04 to about 0.07, from about 0.05 to about 0.07, from about 0.06 to about 0.07, from 0 to about 0.06, from about 0.01 to about 0.06, from about 0.02 to about 0.06, from about 0.03 to about 0.06, from about 0.04 to about 0.06, from about 0.05 to about 0.06, from 0 to about 0.05, from about 0.01 to about 0.05, from about 0.02 to about 0.05, from about 0.03 to about 0.05, from about 0.04 to about 0.05, from 0 to about 0.04, from about 0.01 to about 0.04, from about 0.02 to about 0.04, from about 0.03 to about 0.04, from 0 to about 0.03, from about 0.01 to about 0.03, from about 0.02 to about 0.03, from 0 to about 0.02, from about 0.01 to about 0.02, from 0 to about 0.01, or at most 0, at most about 0.01, at most about 0.02, at most about 0.03, at most about 0.04, at most about 0.05, at most about 0.06, at most about 0.07, at most about 0.08, at most about 0.09, at most about 0.1, or 0, about 0.01, about 0.02, about 0.03, about 0.04, about 0.05, about 0.06, about 0.07, about 0.08, about 0.09, about 0.1 , or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0054] In some embodiments, the RE2content in the alloy composition of Formula (I) may be in a range of 0 wt%, at least 0.01 wt%, in a range of 0 wt% to about 5.00 wt%, from 0 wt% to about 4.95 wt%, from 0 wt% to about 4.90 wt%, from 0 wt% to about 4.85 wt%, from 0 wt% to about 4.80 wt%, from 0 wt% to about 4.75 wt%, from 0 wt% to about 4.70 wt%, from 0 wt% to about 4.65 wt%, from 0 wt% to about 4.60 wt%, from 0 wt% to about 4.55 wt%, from 0 wt% to about 4.50 wt%, from 0 wt% to about 4.45 wt%, from 0 wt% to about 4.40 wt%, from 0 wt% to about 4.35 wt%, from 0 wt% to about 4.30 wt%, from 0 wt% to about 4.25 wt%, from 0 wt% to about 4.20 wt%, from 0 wt% to about 4.15 wt%, from 0 wt% to about 4.10 wt%, from 0 wt% to about 4.05 wt%, from 0 wt% to about 4.00 wt%, from 0 wt% to about 3.95 wt%, from 0 wt% to about 3.90 wt%, from 0 wt% to about 3.85 wt%, from 0 wt% to about 3.80 wt%, from 0 wt% to about 3.75 wt%, from 0 wt% to about 3.70 wt%, from 0 wt% to about 3.65 wt%, from 0 wt% to about 3.60 wt%, from 0 wt% to about 3.55 wt%, from 0 wt% to about 3.50 wt%, from 0 wt% to about 3.45 wt%, from 0 wt% to about 3.40 wt%, from 0 wt% to about 3.35 wt%, from 0 wt% to about 3.30 wt%, from 0 wt% to about 3.25 wt%, from 0 wt% to about 3.20 wt%, from 0 wt% to about 3.15 wt%, from 0 wt% to about 3.10 wt%, from 0 wt% to about 3.05 wt%, from 0 wt% to about 3.00 wt%, from 0 wt% to about 2.95 wt%, from 0 wt% to about 2.90 wt%, from 0 wt% to about 2.85 wt%, from 0 wt% to about 2.80 wt%, from 0 wt% to about 2.75 wt%, from 0 wt% to about 2.70 wt%, from 0 wt% to about 2.65 wt%, from 0 wt% to about 2.60 wt%, from 0 wt% to about 2.55 wt%, from 0 wt% to about 2.50 wt%, from 0 wt% to about 2.45 wt%, from 0 wt% to about 2.40 wt%, from 0 wt% to about 2.35 wt%, from 0 wt% to about 2.30 wt%, from 0 wt% to about 2.25 wt%, from 0 wt% to about 2.20 wt%, from 0 wt% to about 2.15 wt%, from 0 wt% to about 2.10 wt%, from 0 wt% to about 2.05 wt%, from 0 wt% to about 2.00 wt%, from 0 wt% to about 1.95 wt%, from 0 wt% to about 1.90 wt%, from 0 wt% to about 1.85 wt%, from 0 wt% to about 1.80 wt%, from 0 wt% to about 1.75 wt%, from 0 wt% to about 1.70 wt%, from 0 wt% to about 1.65 wt%, from 0 wt% to about 1.60 wt%, from 0 wt% to about 1.55 wt%, from 0 wt% to about 1.50 wt%, from 0 wt% to about 1.45 wt%, from 0 wt% to about 1.40 wt%, from 0 wt% to about 1.35 wt%, from 0 wt% to about 1.30 wt%, from 0 wt% to about 1.25 wt%, from 0 wt% to about 1.20 wt%, from 0 wt% to about 1.15 wt%, from 0 wt% to about 1.10 wt%, from 0 wt% to about 1 .05 wt%, from 0 wt% to about 1.00 wt%, from 0 wt% to about 0.95 wt%, from 0 wt% to about 0.90 wt%, from 0 wt% to about 0.85 wt%, from 0 wt% to about 0.80 wt%, from 0 wt% to about 0.75 wt%, from 0 wt% to about 0.70 wt%, from 0 wt% to about 0.65 wt%, from 0 wt% to about 0.60 wt%, from 0 wt% to about 0.55 wt%, from 0 wt% to about 0.50 wt%, from 0 wt% to about 0.45 wt%, from 0 wt% to about 0.40 wt%, from 0 wt% to about 0.35 wt%, from 0 wt% to about 0.30 wt%, from 0 wt% to about 0.25 wt%, from 0 wt% to about 0.20 wt%, from 0 wt% to about 0.15 wt%, from 0 wt% to about 0.10 wt%, from 0 wt% to about 0.05 wt%, or from about 0.05 wt% to about 5.00 wt%, from about 0.10 wt% to about 5.00 wt%, from about 0.15 wt% to about 5.00 wt%, from about 0.20 wt% to about 5.00 wt%, from about 0.25 wt% to about 5.00 wt%, from about 0.30 wt% to about 5.00 wt%, from about 0.35 wt% to about 5.00 wt%, from about 0.40 wt% to about 5.00 wt%, from about 0.45 wt% to about 5.00 wt%, from about 0.50 wt% to about 5.00 wt%, from about 0.55 wt% to about 5.00 wt%, from about 0.60 wt% to about 5.00 wt%, from about 0.65 wt% to about 5.00 wt%, from about 0.70 wt% to about 5.00 wt%, from about 0.75 wt% to about 5.00 wt%, from about 0.80 wt% to about 5.00 wt%, from about 0.85 wt% to about 5.00 wt%, from about 0.90 wt% to about 5.00 wt%, from about 0.95 wt% to about 5.00 wt%, from about 1.00 wt% to about 5.00 wt%, from about 1.05 wt% to about 5.00 wt%, from about 1.10 wt% to about 5.00 wt%, from about 1.15 wt% to about 5.00 wt%, from about 1.20 wt% to about 5.00 wt%, from about 1.25 wt% to about 5.00 wt%, from about 1.30 wt% to about 5.00 wt%, from about 1.35 wt% to about 5.00 wt%, from about 1.40 wt% to about 5.00 wt%, from about 1.45 wt% to about 5.00 wt%, from about 1.50 wt% to about 5.00 wt%, from about 1.55 wt% to about 5.00 wt%, from about 1 .60 wt% to about 5.00 wt%, from about 1 .65 wt% to about 5.00 wt%, from about 1.70 wt% to about 5.00 wt%, from about 1.75 wt% to about 5.00 wt%, from about 1.80 wt% to about 5.00 wt%, from about 1.85 wt% to about 5.00 wt%, from about 1.90 wt% to about 5.00 wt%, from about 1.95 wt% to about 5.00 wt%, from about 2.00 wt% to about 5.00 wt%, from about 2.05 wt% to about 5.00 wt%, from about 2.10 wt% to about 5.00 wt%, from about 2.15 wt% to about 5.00 wt%, from about 2.20 wt% to about 5.00 wt%, from about 2.25 wt% to about 5.00 wt%, from about 2.30 wt% to about 5.00 wt%, from about 2.35 wt% to about 5.00 wt%, from about 2.40 wt% to about 5.00 wt%, from about 2.45 wt% to about 5.00 wt%, from about 2.50 wt% to about 5.00 wt%, from about 2.55 wt% to about 5.00 wt%, from about 2.60 wt% to about 5.00 wt%, from about 2.65 wt% to about 5.00 wt%, from about 2.70 wt% to about 5.00 wt%, from about 2.75 wt% to about 5.00 wt%, from about 2.80 wt% to about 5.00 wt%, from about 2.85 wt% to about 5.00 wt%, from about 2.90 wt% to about 5.00 wt%, from about 2.95 wt% to about 5.00 wt%, from about 3.00 wt% to about 5.00 wt%, from about 3.05 wt% to about 5.00 wt%, from about 3.10 wt% to about 5.00 wt%, from about 3.15 wt% to about 5.00 wt%, from about 3.20 wt% to about 5.00 wt%, from about 3.25 wt% to about 5.00 wt%, from about 3.30 wt% to about 5.00 wt%, from about 3.35 wt% to about 5.00 wt%, from about 3.40 wt% to about 5.00 wt%, from about 3.45 wt% to about 5.00 wt%, from about 3.50 wt% to about 5.00 wt%, from about 3.55 wt% to about 5.00 wt%, from about 3.60 wt% to about 5.00 wt%, from about 3.65 wt% to about 5.00 wt%, from about 3.70 wt% to about 5.00 wt%, from about 3.75 wt% to about 5.00 wt%, from about 3.80 wt% to about 5.00 wt%, from about 3.85 wt% to about 5.00 wt%, from about 3.90 wt% to about 5.00 wt%, from about 3.95 wt% to about 5.00 wt%, from about 4.00 wt% to about 5.00 wt%, from about 4.05 wt% to about 5.00 wt%, from about 4.10 wt% to about 5.00 wt%, from about 4.15 wt% to about 5.00 wt%, from about 4.20 wt% to about 5.00 wt%, from about 4.25 wt% to about 5.00 wt%, from about 4.30 wt% to about 5.00 wt%, from about 4.35 wt% to about 5.00 wt%, from about 4.40 wt% to about 5.00 wt%, from about 4.45 wt% to about 5.00 wt%, from about 4.50 wt% to about 5.00 wt%, from about 4.55 wt% to about 5.00 wt%, from about 4.60 wt% to about 5.00 wt%, from about 4.65 wt% to about 5.00 wt%, from about 4.70 wt% to about 5.00 wt%, from about 4.75 wt% to about 5.00 wt%, from about 4.80 wt% to about 5.00 wt%, from about 4.85 wt% to about 5.00 wt%, from about 4.90 wt% to about 5.00 wt%, from about 4.95 wt% to about 5.00 wt%, or 0 wt%, about 0.05 wt%, about 0.10 wt%, about 0.15 wt%, about 0.20 wt%, about 0.25 wt%, about 0.30 wt%, about 0.35 wt%, about 0.40 wt%, about 0.45 wt%, about 0.50 wt%, about 0.55 wt%, about 0.60 wt%, about 0.65 wt%, about 0.70 wt%, about 0.75 wt%, about 0.80 wt%, about 0.85 wt%, about 0.90 wt%, about 0.95 wt%, about 1.00 wt%, about 1.05 wt%, about 1.10 wt%, about 1.15 wt%, about 1.20 wt%, about 1.25 wt%, about 1.30 wt%, about 1.35 wt%, about 1.40 wt%, about 1.45 wt%, about 1.50 wt%, about 1.55 wt%, about 1.60 wt%, about 1.65 wt%, about 1.70 wt%, about 1.75 wt%, about 1.80 wt%, about 1.85 wt%, about 1.90 wt%, about 1.95 wt%, about 2.00 wt%, about 2.05 wt%, about 2.10 wt%, about 2.15 wt%, about 2.20 wt%, about 2.25 wt%, about 2.30 wt%, about 2.35 wt%, about 2.40 wt%, about 2.45 wt%, about 2.50 wt%, about 2.55 wt%, about 2.60 wt%, about 2.65 wt%, about 2.70 wt%, about 2.75 wt%, about 2.80 wt%, about 2.85 wt%, about 2.90 wt%, about 2.95 wt%, about 3.00 wt%, about 3.05 wt%, about 3.10 wt%, about 3.15 wt%, about 3.20 wt%, about 3.25 wt%, about 3.30 wt%, about 3.35 wt%, about 3.40 wt%, about 3.45 wt%, about 3.50 wt%, about 3.55 wt%, about 3.60 wt%, about 3.65 wt%, about 3.70 wt%, about 3.75 wt%, about 3.80 wt%, about 3.85 wt%, about 3.90 wt%, about 3.95 wt%, about 4.00 wt%, about 4.05 wt%, about 4.10 wt%, about 4.15 wt%, about 4.20 wt%, about 4.25 wt%, about 4.30 wt%, about 4.35 wt%, about 4.40 wt%, about 4.45 wt%, about 4.50 wt%, about 4.55 wt%, about 4.60 wt%, about 4.65 wt%, about 4.70 wt%, about 4.75 wt%, about 4.80 wt%, about 4.85 wt%, about 4.90 wt%, about 4.95 wt%, about 5.00 wt%, or any value or range therein. It is to he appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that are within the stated rangc(s).

[0055] In some embodiments, v may be 0. In such embodiments, Formula (I) may be represented by Formula (IA):

[0056] RE^Feioo-y-z-wZrwBz —Formula (IA) wherein:

[0057] RE1represents (Cei.xLax);

[0058] 0 < x < 0.5;

[0059] 10 < y < 20;

[0060] 0 < w < 5; and

[0061] 4 < z < 8, wherein w, x, y, and z are atom%.

[0062] In some embodiments, x in the alloy composition of Formula (I) or Formula (LA) may be in a range of more than 0, at least about 0.05, at least about 0.10, at least about 0.15, at least about 0.20, at least about 0.25, at least about 0.30, at least about 0.35, at least about 0.40, at least about 0.45, at least about 0.50, or from more than 0 to about 0.50, from about 0.05 to about 0.50, from about 0.10 to about 0.50, from about 0.15 to about 0.50, from about 0.20 to about 0.50, from about 0.25 to about 0.50, from about 0.30 to about 0.50, from about 0.35 to about 0.50, from about 0.40 to about 0.50, from about 0.45 to about 0.50, from more than 0 to about 0.45, from about 0.05 to about 0.45, from about 0.10 to about 0.45, from about 0.15 to about 0.45, from about 0.20 to about 0.45, from about 0.25 to about 0.45, from about 0.30 to about 0.45, from about 0.35 to about 0.45, from about 0.40 to about 0.45, from more than 0 to about 0.40, from about 0.05 to about 0.40, from about 0.10 to about 0.40, from about 0.15 to about 0.40, from about 0.20 to about 0.40, from about 0.25 to about 0.40, from about 0.30 to about 0.40, from about 0.35 to about 0.40, from more than 0 to about 0.35, from about 0.05 to about 0.35, from about 0.10 to about 0.35, from about 0.15 to about 0.35, from about 0.20 to about 0.35, from about 0.25 to about 0.35, from about 0.30 to about 0.35, from more than 0 to about 0.30, from about 0.05 to about 0.30, from about 0.10 to about 0.30, from about 0.15 to about 0.30, from about 0.20 to about 0.30, from about 0.25 to about 0.30, from more than 0 to about 0.25, from about 0.05 to about 0.25, from about 0.10 to about 0.25, from about 0.15 to about 0.25, from about 0.20 to about 0.25, from more than 0 to about 0.20, from about 0.05 to about 0.20, from about 0.10 to about 0.20, from about 0.15 to about 0.20, from more than 0 to about 0.15, from about 0.05 to about 0.15, from about 0.10 to about 0.15, from more than 0 to about 0.10, from about 0.05 to about 0.10, from more than 0 to about 0.05, or at most 0.01, at most about 0.05, at most about 0. 10, at most about 0.15, at most about 0.20, at most about 0.25, at most about 0.30, at most about 0.35, at most about 0.40, at most about 0.45, at most about 0.50, or about 0.01, about 0.05, about 0.10, about 0.15, about 0.20, about 0.25, about 0.30, about 0.35, about 0.40, about 0.45, about 0.50, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that are within the stated rangc(s).

[0063] In some embodiments, u in the alloy composition of Formula (I) may be in a range of more than 0, at least about 0.10, at least about 0.20, at least about 0.25, at least about 0.30, at least about 0.40, at least about 0.50, at least about 0.60, at least about 0.70, at least about 0.80, at least about 0.90, at least about 1.00, or from more than 0 to about 1.00, from about 0.10 to about 1.00, from about 0.20 to about 1.00, from about 0.25 to about 1.00, from about 0.30 to about 1.00, from about 0.40 to about 1.00, from about 0.50 to about 1.00, from about 0.60 to about 1.00, from about 0.70 to about 1.00, from about 0.80 to about 1.00, from about 0.90 to about 1.00, from more than 0 to about 0.90, from about 0.10 to about 0.90, from about 0.20 to about 0.90, from about 0.25 to about 0.90, from about 0.30 to about 0.90, from about 0.40 to about 0.90, from about 0.50 to about 0.90, from about 0.60 to about 0.90, from about 0.70 to about 0.90, from about 0.80 to about 0.90, from more than 0 to about 0.80, from about 0.10 to about 0.80, from about 0.20 to about 0.80, from about 0.25 to about 0.80, from about 0.30 to about 0.80, from about 0.40 to about 0.80, from about 0.50 to about 0.80, from about 0.60 to about 0.80, from about 0.70 to about 0.80, from more than 0 to about 0.70, from about 0.10 to about 0.70, from about 0.20 to about 0.70, from about 0.25 to about 0.70, from about 0.30 to about 0.70, from about 0.40 to about 0.70, from about 0.50 to about 0.70, from about 0.60 to about 0.70, from more than 0 to about 0.60, from about 0.10 to about 0.60, from about 0.20 to about 0.60, from about 0.25 to about 0.60, from about 0.30 to about 0.60, from about 0.40 to about 0.60, from about 0.50 to about 0.60, from more than 0 to about 0.50, from about 0.10 to about 0.50, from about 0.20 to about 0.50, from about 0.25 to about 0.50, from about 0.30 to about 0.50, from about 0.40 to about 0.50, from more than 0 to about 0.40, from about 0.10 to about 0.40, from about 0.20 to about 0.40, from about 0.25 to about 0.40, from about 0.30 to about 0.40, from more than 0 to about 0.30, from about 0.10 to about 0.30, from about 0.20 to about 0.30, from about 0.25 to about 0.30, from more than 0 to about 0.25, from about 0.10 to about 0.25, from about 0.20 to about 0.25, from more than 0 to about 0.20, from about 0.10 to about 0.20, from more than 0 to about 0.10, or at most 0.01, at most about 0.10, at most about 0.20, at most about 0.25, at most about 0.30, at most about 0.40, at most about 0.50, at most about 0.60, at most about 0.70, at most about 0.80, at most about 0.90, at most about 1.00, or about O.Ol , about O.10, about 0.20, about O.2.5, about 0.30, about 0.40, about 0.50, about 0.60, about 0.70, about 0.80, about 0.90, about 1.00, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub -ranges or discrete values (which may or may not be a whole number) that arc within the stated rangc(s).

[0064] In some embodiments, y in the alloy composition of Formula (I) or Formula (IA) may be in a range of at least about 10, at least about 11, at least about 12, at least about 13, at least about 14, at least about 14.3, at least about 15, at least about 16, at least about 17, at least about 18, at least about

[0065] 19, at least about 20, or from about 10 to about 20, from about 11 to about 20, from about 12 to about

[0066] 20, from about 13 to about 20, from about 14 to about 20, from about 14.3 to about 20, from about 15 to about 20, from about 16 to about 20, from about 17 to about 20, from about 18 to about 20, from about 19 to about 20, from about 10 to about 19, from about 11 to about 19, from about 12 to about 19, from about 13 to about 19, from about 14 to about 19, from about 14.3 to about 19, from about 15 to about 19, from about 16 to about 19, from about 17 to about 19, from about 18 to about 19, from about 10 to about 18, from about 11 to about 18, from about 12 to about 18, from about 13 to about 18, from about 14 to about 18, from about 14.3 to about 18, from about 15 to about 18, from about 16 to about 18, from about 17 to about 18, from about 10 to about 17, from about 11 to about 17, from about 12 to about 17, from about 13 to about 17, from about 14 to about 17, from about 14.3 to about 17, from about 15 to about 17, from about 16 to about 17, from about 10 to about 16, from about 11 to about 16, from about 12 to about 16, from about 13 to about 16, from about 14 to about 16, from about 14.3 to about 16, from about 15 to about 16, from about 10 to about 15, from about 11 to about 15, from about 12 to about 15, from about 13 to about 15, from about 14 to about 15, from about 14.3 to about 15, from about 10 to about 14.3, from about 11 to about 14.3, from about 12 to about 14.3, from about 13 to about 14.3, from about 14 to about 14.3, from about 10 to about 14, from about 11 to about 14, from about 12 to about 14, from about 13 to about 14, from about 10 to about 13, from about 11 to about 13, from about 12 to about 13, from about 10 to about 12, from about 11 to about

[0067] 12, from about 10 to about 11, or at most about 10, at most about 11, at most about 12, at most about

[0068] 13, at most about 14, at most about 14.3, at most about 15, at most about 16, at most about 17, at most about 18, at most about 19, at most about 20, or about 10, about 11, about 12, about 13, about 14, about 14.3, about 15, about 16, about 17, about 18, about 19, about 20, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0069] In some embodiments, w in the alloy composition of Formula (I) or Formula (IA) may be in a range of more than 0, at least about 0.5, at least about 0.7, at least about 1 .0, at least about 1.5, at least about 2.0, at least about 2.5, at least about 3.0, at least about 3.5, at least about 4.0, at least about

[0070] 4.5, at least about 5.0, or from more than 0 to about 5.0, from about 0.5 to about 5.0, from about 0.7 to about 5.0, from about 1.0 to about 5.0, from about 1.5 to about 5.0, from about 2.0 to about 5.0, from about 2.5 to about 5.0, from about 3.0 to about 5.0, from about 3.5 to about 5.0, from about 4.0 to about 5.0, from about 4.5 to about 5.0, from more than 0 to about 4.5, from about 0.5 to about 4.5, from about 0.7 to about 4.5, from about 1.0 to about 4.5, from about 1.5 to about 4.5, from about 2.0 to about 4.5, from about 2.5 to about 4.5, from about 3.0 to about 4.5, from about 3.5 to about 4.5, from about 4.0 to about 4.5, from more than 0 to about 4.0, from about 0.5 to about 4.0, from about 0.7 to about 4.0, from about 1.0 to about 4.0, from about 1.5 to about 4.0, from about 2.0 to about 4.0, from about 2.5 to about 4.0, from about 3.0 to about 4.0, from about 3.5 to about 4.0, from more than 0 to about 3.5, from about 0.5 to about 3.5, from about 0.7 to about 3.5, from about 1.0 to about 3.5, from about 1.5 to about 3.5, from about 2.0 to about 3.5, from about 2.5 to about 3.5, from about 3.0 to about 3.5, from more than 0 to about 3.0, from about 0.5 to about 3.0, from about 0.7 to about 3.0, from about 1.0 to about 3.0, from about 1.5 to about 3.0, from about 2.0 to about 3.0, from about 2.5 to about 3.0, from more than 0 to about 2.5, from about 0.5 to about 2.5, from about 0.7 to about 2.5, from about 1.0 to about 2.5, from about 1.5 to about 2.5, from about 2.0 to about 2.5, from more than 0 to about 2.0, from about 0.5 to about 2.0, from about 0.7 to about 2.0, from about 1.0 to about 2.0, from about 1.5 to about 2.0, from more than 0 to about 1.5, from about 0.5 to about 1.5, from about 0.7 to about 1.5, from about 1.0 to about 1.5, from more than 0 to about 1.0, from about 0.5 to about 1.0, from about 0.7 to about 1.0, from more than 0 to about 0.7, from about 0.5 to about 0.7, from more than 0 to about 0.5, or at most 0.01, at most about 0.5, at most about 0.7, at most about 1.0, at most about 1.5, at most about 2.0, at most about 2.5, at most about 3.0, at most about 3.5, at most about 4.0, at most about 4.5, at most about 5.0, or about 0.01, about 0.5, about 0.7, about 1.0, about

[0071] 1.5, about 2.0, about 2.5, about 3.0, about 3.5, about 4.0, about 4.5, about 5.0, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0072] In some embodiments, z in the alloy composition of Formula (I) or Formula (IA) may be in a range of at least about 4.0, at least about 4.5, at least about 5.0, at least about 5.5, at least about 6.0, at least about 6.1, at least about 6.5, at least about 7.0, at least about 7.5, at least about 8.0, or from about 4.0 to about 8.0, from about 4.5 to about 8.0, from about 5.0 to about 8.0, from about 5.5 to about 8.0, from about 6.0 to about 8.0, from about 6.1 to about 8.0, from about 6.5 to about 8.0, from about 7.0 to about 8.0, from about 7.5 to about 8.0, from about 4.0 to about 7.5, from about 4.5 to about 7.5, from about 5.0 to about 7.5, from about 5.5 to about 7.5, from about 6.0 to about 7.5, from about 6.1 to about 7.5, from about 6.5 to about 7.5, from about 7.0 to about 7.5, from about 4.0 to about 7.0, from about 4.5 to about 7.0, from about 5.0 to about 7.0, from about 5.5 to about 7.0, from about 6.0 to about 7.0, from about 6.1 to about 7.0, from about 6.5 to about 7.0, from about 4.0 to about 6.5, from about 4.5 to about 6.5, from about 5.0 to about 6.5, from about 5.5 to about 6.5, from about 6.0 to about 6.5, from about 6.1 to about 6.5, from about 4.0 to about 6.1, from about 4.5 to about 6.1, from about 5.0 to about 6.1, from about 5.5 to about 6.1, from about 6.0 to about 6.1, from about 4.0 to about 6.0, from about 4.5 to about 6.0, from about 5.0 to about 6.0, from about 5.5 to about 6.0, from about 4.0 to about 5.5, from about 4.5 to about 5.5, from about 5.0 to about 5.5, from about 4.0 to about 5.0, from about 4.5 to about 5.0, from about 4.0 to about 4.5, or at most about 4.0, at most about 4.5, at most about 5.0, at most about 5.5, at most about 6.0, at most about 6.1, at most about 6.5, at most about 7.0, at most about 7.5, at most about 8.0, or about 4.0, about 4.5, about 5.0, about 5.5, about 6.0, about 6.1, about 6.5, about 7.0, about 7.5, about 8.0, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0073] In some embodiments, the alloy composition may be selected from the group consisting of:

[0074] • (Ceo,9Lao.i)i4Fe78.9ZrjB6.i

[0075] • (Ccn.RLao.2)i4Fc78.9ZriB6.i

[0076] • (Ceo.7Lao.3)i4Fe78.9ZrjB6.i

[0077] • (Ceo.8Lao.2)i4.3Fe78.9Zro.7B6.i; and

[0078] • [(Ceo.sLao.2)o.9(Ndo.75Pro.25)o.i]i4.3Fe78.9Zrci.7B6.i

[0079] The inventors have surprisingly found that the disclosed magnetic powders may be produced with a low cost by using cerium and lanthanum as the rare-earth metals. In some embodiments, the disclosed magnetic powders only contain cerium and lanthanum as the rare-earth metals.

[0080] The inventors have further surprisingly found that the inclusion of zirconium in the alloy composition results in the disclosed magnetic powders and bonded magnets exhibiting improved quench stability, advantageously resulting in more stable and repeatable magnetic properties in a broader processing range, and making it suitable for robust mass production.

[0081] The inventors have also surprisingly found that by the inclusion of zirconium in the alloy composition, the disclosed magnetic powders may exhibit a decreased grain size, which advantageously allows the disclosed bonded magnets to exhibit improved compressibility and higher densities. This allows bonded magnets to be formed at a higher magnet density with the same pressing pressure.

[0082] In some embodiments, the disclosed alloy composition may exhibit crystal grain sizes in a range of at least about 20 nm, at least about 21 nm, at least about 21.7 nm, at least about 22 nm, at least about 22.6 nm, at least about 23 nm, at least about 23.1 nm, at least about 23.7 nm, at least about 24 nm, at least about 25 nm, at least about 26 nm, at least about 27 nm, at least about 28 nm, at least about 29 nm, at least about 30 nm, or from about 20 nm to about 30 nm, from about 21 nm to about 30 nm, from about 21.7 nm to about 30 nm, from about 22 nm to about 30 nm, from about 22.6 nm to about 30 nm, from about 23 nm to about 30 nm, from about 23.1 nm to about 30 nm, from about 23.7 nm to about 30 nm, from about 24 nm to about 30 nm, from about 25 nm to about 30 nm, from about 26 nm to about 30 nm, from about 27 nm to about 30 nm, from about 28 nm to about 30 nm, from about 29 nm to about 30 nm, from about 20 nm to about 29 nm, from about 21 nm to about 29 nm, from about 21.7 nm to about 29 nm, from about 22 nm to about 29 nm, from about 22.6 nm to about 29 nm, from about 23 nm to about 29 nm, from about 23.1 nm to about 29 nm, from about 23.7 nm to about 29 nm, from about 24 nm to about 29 nm, from about 25 nm to about 29 nm, from about

[0083] 26 nm to about 29 nm, from about 27 nm to about 29 nm, from about 28 nm to about 29 nm, from about 20 nm to about 28 nm, from about 21 nm to about 28 nm, from about 21.7 nm to about 28 nm, from about 22 nm to about 28 nm, from about 22.6 nm to about 28 nm, from about 23 nm to about 28 nm, from about 23.1 nm to about 28 nm, from about 23.7 nm to about 28 nm, from about 24 nm to about 28 nm, from about 25 nm to about 28 nm, from about 26 nm to about 28 nm, from about 27 nm to about 28 nm, from about 20 nm to about 27 nm, from about 21 nm to about 27 nm, from about 21.7 nm to about 27 nm, from about 22 nm to about 27 nm, from about 22.6 nm to about 27 nm, from about 23 nm to about 27 nm, from about 23.1 nm to about 27 nm, from about 23.7 nm to about 27 nm, from about 24 nm to about 27 nm, from about 25 nm to about 27 nm, from about 26 nm to about

[0084] 27 nm, from about 20 nm to about 26 nm, from about 21 nm to about 26 nm, from about 21.7 nm to about 26 nm, from about 22 nm to about 26 nm, from about 22.6 nm to about 26 nm, from about 23 nm to about 26 nm, from about 23.1 nm to about 26 nm, from about 23.7 nm to about 26 nm, from about 24 nm to about 26 nm, from about 25 nm to about 26 nm, from about 20 nm to about 25 nm, from about 21 nm to about 25 nm, from about 21 .7 nm to about 25 nm, from about 22 nm to about 25 nm, from about 22.6 nm to about 25 nm, from about 23 nm to about 25 nm, from about 23.1 nm to about 25 nm, from about 23.7 nm to about 25 nm, from about 24 nm to about 25 nm, from about 20 nm to about 24 nm, from about 21 nm to about 24 nm, from about 21.7 nm to about 24 nm, from about 22 nm to about 24 nm, from about 22.6 nm to about 24 nm, from about 23 nm to about 24 nm, from about 23. 1 nm to about 24 nm, from about 23.7 nm to about 24 nm, from about 20 nm to about 23.7 nm, from about 21 nm to about 23.7 nm, from about 21.7 nm to about 23.7 nm, from about 22 nm to about 23.7 nm, from about 22.6 nm to about 23.7 nm, from about 23 nm to about 23.7 nm, from about 23.1 nm to about 23.7 nm, from about 20 nm to about 23.1 nm, from about 21 nm to about 23.1 nm, from about 21.7 nm to about 23.1 nm, from about 22 nm to about 23.1 nm, from about 22.6 nm to about 23.1 nm, from about 23 nm to about 23.1 nm, from about 20 nm to about 23 nm, from about 21 nm to about 23 nm, from about 21.7 nm to about 23 nm, from about 22 nm to about 23 nm, from about 22.6 nm to about 23 nm, from about 20 nm to about 22.6 nm, from about 21 nm to about 22.6 nm, from about 21.7 nm to about 22.6 nm, from about 22 nm to about 22.6 nm, from about 20 nm to about 22 nm, from about 21 nm to about 22 nm, from about 21.7 nm to about 22 nm, from about 20 nm to about 21.7 nm, from about 21 nm to about 21.7 nm, from about 20 nm to about 21 nm, or at most about 20 nm, at most about 21 nm, at most about 21.7 nm, at most about 22 nm, at most about 22.6 nm, at most about 23 nm, at most about 23.1 nm, at most about 23.7 nm, at most about 24 nm, at most about 25 nm, at most about 26 nm, at most about 27 nm, at most about 28 nm, at most about 29 nm, at most about 30 nm, or about 20 nm, about 21 nm, about 21.7 nm, about 22 nm, about 22.6 nm, about 23 nm, about 23.1 nm, about 23.7 nm, about 24 nm, about 25 nm, about 26 nm, about 27 nm, about 28 nm, about 29 nm, about 30 nm, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that arc within the stated range(s).

[0085] The present invention further provides a magnetic powder comprising the alloy composition as disclosed herein.

[0086] The inventors of the present invention have surprisingly found that by including lanthanum and zirconium in the alloy composition, cerium-containing magnetic powders and bonded magnets of the present invention advantageously exhibit improved thermal stability and retain high Hcivalues at high temperatures of up to 120 °C.

[0087] The inventors have also surprisingly found that the inclusion of lanthanum in the alloy composition causes the disclosed magnetic powders and bonded magnets to exhibit improved remanence (Br) and max energy product ( BH)maxvalues, which improves the strength and magnetic flux density of the disclosed magnetic powders and bonded magnets.

[0088] In some embodiments, the magnetic powder may exhibit remanence (Br) values in a range of at least about 5.00 kG, at least about 5.20 kG, at least about 5.40 kG, at least about 5.60 kG, at least about 5.73 kG, at least about 5.80 kG, at least about 5.85 kG, at least about 5.97 kG, at least about 6.00 kG, at least about 6.19 kG, at least about 6.20 kG, at least about 6.40 kG, at least about 6.60 kG, or from about 5.00 kG to about 6.60 kG, from about 5.20 kG to about 6.60 kG, from about 5.40 kG to about 6.60 kG, from about 5.60 kG to about 6.60 kG, from about 5.73 kG to about 6.60 kG, from about 5.80 kG to about 6.60 kG, from about 5.85 kG to about 6.60 kG, from about 5.97 kG to about

[0089] 6.60 kG, from about 6.00 kG to about 6.60 kG, from about 6. 19 kG to about 6.60 kG, from about 6.20 kG to about 6.60 kG, from about 6.40 kG to about 6.60 kG, from about 5.00 kG to about 6.40 kG, from about 5.20 kG to about 6.40 kG, from about 5.40 kG to about 6.40 kG, from about 5.60 kG to about 6.40 kG, from about 5.73 kG to about 6.40 kG, from about 5.80 kG to about 6.40 kG, from about 5.85 kG to about 6.40 kG, from about 5.97 kG to about 6.40 kG, from about 6.00 kG to about 6.40 kG, from about 6.19 kG to about 6.40 kG, from about 6.20 kG to about 6.40 kG, from about 5.00 kG to about 6.20 kG, from about 5.20 kG to about 6.20 kG, from about 5.40 kG to about 6.20 kG, from about 5.60 kG to about 6.20 kG, from about 5.73 kG to about 6.20 kG, from about 5.80 kG to about 6.20 kG, from about 5.85 kG to about 6.20 kG, from about 5.97 kG to about 6.20 kG, from about 6.00 kG to about 6.20 kG, from about 6.19 kG to about 6.20 kG, from about 5.00 kG to about 6.19 kG, from about 5.20 kG to about 6.19 kG, from about 5.40 kG to about 6.19 kG, from about 5.60 kG to about 6.19 kG, from about 5.73 kG to about 6.19 kG, from about 5.80 kG to about 6.19 kG, from about 5.85 kG to about 6.19 kG, from about 5.97 kG to about 6.19 kG, from about 6.00 kG to about 6.19 kG, from about 5.00 kG to about 6.00 kG, from about 5.20 kG to about 6.00 kG, from about 5.40 kG to about 6.00 kG, from about 5.60 kG to about 6.00 kG, from about 5.73 kG to about 6.00 kG, from about 5.80 kG to about 6.00 kG, from about 5.85 kG to about 6.00 kG, from about 5.97 kG to about 6.00 kG, from about 5.00 kG to about 5.97 kG, from about 5.20 kG to about 5.97 kG, from about 5.40 kG to about 5.97 kG, from about 5.60 kG to about 5.97 kG, from about 5.73 kG to about 5.97 kG, from about 5.80 kG to about 5.97 kG, from about 5.85 kG to about 5.97 kG, from about 5.00 kG to about 5.85 kG, from about 5.20 kG to about 5.85 kG, from about 5.40 kG to about 5.85 kG, from about 5.60 kG to about 5.85 kG, from about 5.73 kG to about 5.85 kG, from about 5.80 kG to about 5.85 kG, from about 5.00 kG to about 5.80 kG, from about 5.20 kG to about 5.80 kG, from about 5.40 kG to about 5.80 kG, from about 5.60 kG to about 5.80 kG, from about 5.73 kG to about 5.80 kG, from about 5.00 kG to about 5.73 kG, from about 5.20 kG to about 5.73 kG, from about 5.40 kG to about 5.73 kG, from about 5.60 kG to about 5.73 kG, from about 5.00 kG to about

[0090] 5.60 kG, from about 5.20 kG to about 5.60 kG, from about 5.40 kG to about 5.60 kG, from about 5.00 kG to about 5.40 kG, from about 5.20 kG to about 5.40 kG, from about 5.00 kG to about 5.20 kG, or at most about 5.00 kG, at most about 5.20 kG, at most about 5.40 kG, at most about 5.60 kG, at most about 5.73 kG, at most about 5.80 kG, at most about 5.85 kG, at most about 5.97 kG, at most about 6.00 kG, at most about 6.19 kG, at most about 6.20 kG, at most about 6.40 kG, at most about 6.60 kG, or about 5.00 kG, about 5.20 kG, about 5.40 kG, about 5.60 kG, about 5.73 kG, about 5.80 kG, about 5.85 kG, about 5.97 kG, about 6.00 kG, about 6. 19 kG, at most about 6.20 kG, about 6.40 kG, about 6.60 kG, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0091] In some embodiments, the magnetic powder may exhibit intrinsic coercivity (HCi) values in a range of at least about 4.0 kOe, at least about 4.1 kOe, at least about 4.5 kOe, at least about 5.0 kOe, at least about 5.2 kOe, at least about 5.3 kOe, at least about 5.5 kOe, at least about 6.0 kOe, at least about 6.5 kOe, at least about 6.7 kOe, at least about 7.0 kOe, or from about 4.0 kOe to about 7.0 kOe, from about 4.1 kOe to about 7.0 kOe, from about 4.5 kOe to about 7.0 kOe, from about 5.0 kOe to about 7.0 kOc, from about 5.2 kOc to about 7.0 kOc, from about 5.3 kOc to about 7.0 kOc, from about

[0092] 5.5 kOe to about 7.0 kOe, from about 6.0 kOe to about 7.0 kOe, from about 6.5 kOe to about 7.0 kOe, from about 6.7 kOe to about 7.0 kOe, from about 4.0 kOe to about 6.7 kOe, from about 4.1 kOe to about 6.7 kOe, from about 4.5 kOe to about 6.7 kOe, from about 5.0 kOe to about 6.7 kOe, from about 5.2 kOe to about 6.7 kOe, from about 5.3 kOe to about 6.7 kOe, from about 5.5 kOe to about 6.7 kOe, from about 6.0 kOe to about 6.7 kOe, from about 6.5 kOe to about 6.7 kOe, from about 4.0 kOe to about 6.5 kOc, from about 4.1 kOc to about 6.5 kOc, from about 4.5 kOc to about 6.5 kOc, from about 5.0 kOe to about 6.5 kOe, from about 5.2 kOe to about 6.5 kOe, from about 5.3 kOe to about 6.5 kOe, from about 5.5 kOe to about 6.5 kOe, from about 6.0 kOe to about 6.5 kOe, from about 4.0 kOe to about 6.0 kOe, from about 4. 1 kOe to about 6.0 kOe, from about 4.5 kOe to about 6.0 kOe, from about 5.0 kOc to about 6.0 kOc, from about 5.2 kOc to about 6.0 kOc, from about 5.3 kOe to about 6.0 kOc, from about 5.5 kOe to about 6.0 kOe, from about 4.0 kOe to about 5.5 kOe, from about 4.1 kOe to about 5.5 kOe, from about 4.5 kOe to about 5.5 kOe, from about 5.0 kOe to about 5.5 kOe, from about

[0093] 5.2 kOe to about 5.5 kOe, from about 5.3 kOe to about 5.5 kOe, from about 4.0 kOe to about 5.3 kOe, from about 4.1 kOe to about 5.3 kOe, from about 4.5 kOe to about 5.3 kOe, from about 5.0 kOe to about 5.3 kOe, from about 5.2 kOe to about 5.3 kOe, from about 4.0 kOe to about 5.2 kOe, from about 4.1 kOe to about 5.2 kOe, from about 4.5 kOe to about 5.2 kOe, from about 5.0 kOe to about 5.2 kOe, from about 4.0 kOe to about 5.0 kOe, from about 4.1 kOe to about 5.0 kOe, from about 4.5 kOe to about 5.0 kOe, from about 4.0 kOe to about 4.5 kOe, from about 4.1 kOe to about 4.5 kOe, from about 4.0 kOe to about 4.1 kOe, or at most about 4.0 kOe, at most about 4.1 kOe, at most about 4.5 kOe, at most about 5.0 kOe, at most about 5.2 kOe, at most about 5.3 kOe, at most about 5.5 kOe, at most about 6.0 kOc, at most about 6.5 kOc, at most about 6.7 kOc, at most about 7.0 kOc, or about 4.0 kOe, about 4.1 kOe, about 4.5 kOe, about 5.0 kOe, about 5.2 kOe, about 5.3 kOe, about 5.5 kOe, about 6.0 kOe, about 6.5 kOe, about 6.7 kOe, about 7.0 kOe, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub -ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0094] In some embodiments, the magnetic powder may exhibit normal coercivity (Hc) values in a range of at least about 3.2 kOe, at least about 3.3 kOe, at least about 3.4 kOe, at least about 3.5 kOe, at least about 3.6 kOe, at least about 3.7 kOe, at least about 3.8 kOe, at least about 3.9 kOe, at least about 4.0 kOe, at least about 4.1 kOe, at least about 4.2 kOe, at least about 4.3 kOe, at least about 4.4 kOc, at least about 4.5 kOc, at least about 4.6 kOe, at least about 4.7 kOc, or from about 3.2 kOc to about 4.7 kOe, from about 3.3 kOe to about 4.7 kOe, from about 3.4 kOe to about 4.7 kOe, from about

[0095] 3.5 kOe to about 4.7 kOe, from about 3.6 kOe to about 4.7 kOe, from about 3.7 kOe to about 4.7 kOe, from about 3.8 kOe to about 4.7 kOe, from about 3.9 kOe to about 4.7 kOe, from about 4.0 kOe to about 4.7 kOe, from about 4.1 kOe to about 4.7 kOe, from about 4.2 kOe to about 4.7 kOe, from about

[0096] 4.3 kOc to about 4.7 kOc, from about 4.4 kOc to about 4.7 kOc, from about 4.5 kOc to about 4.7 kOc, from about 4.6 kOe to about 4.7 kOe, from about 3.2 kOe to about 4.6 kOe, from about 3.3 kOe to about 4.6 kOe, from about 3.4 kOe to about 4.6 kOe, from about 3.5 kOe to about 4.6 kOe, from about

[0097] 3.6 kOe to about 4.6 kOe, from about 3.7 kOe to about 4.6 kOe, from about 3.8 kOe to about 4.6 kOe, from about 3.9 kOe to about 4.6 kOe, from about 4.0 kOe to about 4.6 kOe, from about 4.1 kOe to about 4.6 kOc, from about 4.2 kOc to about 4.6 kOc, from about 4.3 kOc to about 4.6 kOe, from about

[0098] 4.4 kOe to about 4.6 kOe, from about 4.5 kOe to about 4.6 kOe, from about 3.2 kOe to about 4.5 kOe, from about 3.3 kOe to about 4.5 kOe, from about 3.4 kOe to about 4.5 kOe, from about 3.5 kOe to about 4.5 kOe, from about 3.6 kOe to about 4.5 kOe, from about 3.7 kOe to about 4.5 kOe, from about 3.8 kOe to about 4.5 kOe, from about 3.9 kOe to about 4.5 kOe, from about 4.0 kOe to about 4.5 kOe, from about 4.1 kOe to about 4.5 kOe, from about 4.2 kOe to about 4.5 kOe, from about 4.3 kOe to about 4.5 kOe, from about 4.4 kOe to about 4.5 kOe, from about 3.2 kOe to about 4.4 kOe, from about 3.3 kOe to about 4.4 kOe, from about 3.4 kOe to about 4.4 kOe, from about 3.5 kOe to about 4.4 kOe, from about 3.6 kOe to about 4.4 kOe, from about 3.7 kOe to about 4.4 kOe, from about 3.8 kOe to about 4.4 kOc, from about 3.9 kOc to about 4.4 kOc, from about 4.0 kOc to about 4.4 kOc, from about

[0099] 4.1 kOe to about 4.4 kOe, from about 4.2 kOe to about 4.4 kOe, from about 4.3 kOe to about 4.4 kOe, from about 3.2 kOe to about 4.3 kOe, from about 3.3 kOe to about 4.3 kOe, from about 3.4 kOe to about 4.3 kOe, from about 3.5 kOe to about 4.3 kOe, from about 3.6 kOe to about 4.3 kOe, from about 3.7 kOe to about 4.3 kOe, from about 3.8 kOe to about 4.3 kOe, from about 3.9 kOe to about 4.3 kOe, from about 4.0 kOe to about 4.3 kOe, from about 4.1 kOe to about 4.3 kOe, from about 4.2 kOe to about 4.3 kOc, from about 3.2 kOc to about 4.2 kOc, from about 3.3 kOc to about 4.2 kOc, from about 3.4 kOe to about 4.2 kOe, from about 3.5 kOe to about 4.2 kOe, from about 3.6 kOe to about 4.2 kOe, from about 3.7 kOe to about 4.2 kOe, from about 3.8 kOe to about 4.2 kOe, from about 3.9 kOe to about 4.2 kOe, from about 4.0 kOe to about 4.2 kOe, from about 4.1 kOe to about 4.2 kOe, from about

[0100] 3.2 kOc to about 4.1 kOc, from about 3.3 kOc to about 4.1 kOc, from about 3.4 kOe to about 4.1 kOc, from about 3.5 kOe to about 4.1 kOe, from about 3.6 kOe to about 4.1 kOe, from about 3.7 kOe to about 4.1 kOe, from about 3.8 kOe to about 4.1 kOe, from about 3.9 kOe to about 4.1 kOe, from about 4.0 kOe to about 4.1 kOe, from about 3.2 kOe to about 4.0 kOe, from about 3.3 kOe to about 4.0 kOe, from about 3.4 kOe to about 4.0 kOe, from about 3.5 kOe to about 4.0 kOe, from about 3.6 kOe to about 4.0 kOe, from about 3.7 kOe to about 4.0 kOe, from about 3.8 kOe to about 4.0 kOe, from about 3.9 kOe to about 4.0 kOe, from about 3.2 kOe to about 3.9 kOe, from about 3.3 kOe to about 3.9 kOe, from about 3.4 kOe to about 3.9 kOe, from about 3.5 kOe to about 3.9 kOe, from about 3.6 kOe to about 3.9 kOe, from about 3.7 kOe to about 3.9 kOe, from about 3.8 kOe to about 3.9 kOe, from about

[0101] 3.2 kOe to about 3.8 kOe, from about 3.3 kOe to about 3.8 kOe, from about 3.4 kOe to about 3.8 kOe, from about 3.5 kOe to about 3.8 kOe, from about 3.6 kOe to about 3.8 kOe, from about 3.7 kOe to about 3.8 kOc, from about 3.2 kOc to about 3.7 kOc, from about 3.3 kOc to about 3.7 kOc, from about

[0102] 3.4 kOe to about 3.7 kOe, from about 3.5 kOe to about 3.7 kOe, from about 3.6 kOe to about 3.7 kOe, from about 3.2 kOe to about 3.6 kOe, from about 3.3 kOe to about 3.6 kOe, from about 3.4 kOe to about 3.6 kOe, from about 3.5 kOe to about 3.6 kOe, from about 3.2 kOe to about 3.5 kOe, from about

[0103] 3.3 kOe to about 3.5 kOe, from about 3.4 kOe to about 3.5 kOe, from about 3.2 kOe to about 3.4 kOe, from about 3.3 kOe to about 3.4 kOe, from about 3.2 kOe to about 3.3 kOe, or at most about 3.2 kOe, at most about 3.3 kOe, at most about 3.4 kOe, at most about 3.5 kOe, at most about 3.6 kOe, at most about 3.7 kOe, at most about 3.8 kOe, at most about 3.9 kOe, at most about 4.0 kOe, at most about

[0104] 4.1 kOe, at most about 4.2 kOe, at most about 4.3 kOe, at most about 4.4 kOe, at most about 4.5 kOe, at most about 4.6 kOe, at most about 4.7 kOe, or about 3.2 kOe, about 3.3 kOe, about 3.4 kOe, about

[0105] 3.5 kOc, about 3.6 kOc, about 3.7 kOc, about 3.8 kOc, about 3.9 kOc, about 4.0 kOc, about 4.1 kOc, about 4.2 kOe, about 4.3 kOe, about 4.4 kOe, about 4.5 kOe, about 4.6 kOe, about 4.7 kOe, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0106] In some embodiments, the magnetic powder may exhibit maximum energy product ((BH)max) values in a range of at least about 5.5 MGOe, at least about 5.7 MGOe, at least about 5.9 MGOe, at least about 6.1 MGOe, at least about 6.2 MGOe, at least about 6.3 MGOe, at least about

[0107] 6.4 MGOe, at least about 6.5 MGOe, at least about 6.7 MGOe, at least about 6.9 MGOe, at least about

[0108] 7.1 MGOe, at least about 7.3 MGOe, at least about 7.4 MGOe, at least about 7.5 MGOe, or from about 5.5 MGOe to about 7.5 MGOe, from about 5.7 MGOe to about 7.5 MGOe, from about 5.9 MGOe to about 7.5 MGOe, from about 6.1 MGOe to about 7.5 MGOe, from about 6.2 MGOe to about 7.5 MGOe, from about 6.3 MGOe to about 7.5 MGOe, from about 6.4 MGOe to about 7.5 MGOe, from about 6.5 MGOe to about 7.5 MGOe, from about 6.7 MGOe to about 7.5 MGOe, from about 6.9 MGOe to about 7.5 MGOe, from about 7.1 MGOe to about 7.5 MGOe, from about 7.3 MGOe to about 7.5 MGOe, from about 7.4 MGOe to about 7.5 MGOe, from about 5.5 MGOe to about 7.4 MGOe, from about 5.7 MGOe to about 7.4 MGOe, from about 5.9 MGOe to about 7.4 MGOe, from about 6.1 MGOe to about 7.4 MGOe, from about 6.2 MGOe to about 7.4 MGOe, from about 6.3 MGOe to about 7.4 MGOe, from about 6.4 MGOe to about 7.4 MGOe, from about 6.5 MGOe to about 7.4 MGOe, from about 6.7 MGOe to about 7.4 MGOe, from about 6.9 MGOe to about 7.4 MGOe, from about 7.1 MGOe to about 7.4 MGOe, from about 7.3 MGOe to about 7.4 MGOe, from about 5.5 MGOe to about 7.3 MGOe, from about 5.7 MGOe to about 7.3 MGOe, from about 5.9 MGOe to about 7.3 MGOe, from about 6.1 MGOe to about 7.3 MGOe, from about 6.2 MGOe to about 7.3 MGOe, from about 6.3 MGOe to about 7.3 MGOe, from about 6.4 MGOe to about 7.3 MGOe, from about 6.5 MGOe to about 7.3 MGOe, from about 6.7 MGOe to about 7.3 MGOe, from about 6.9 MGOe to about 7.3 MGOe, from about 7.1 MGOe to about 7.3 MGOe, from about 5.5 MGOe to about 7.1 MGOe, from about 5.7 MGOe to about 7.1 MGOe, from about 5.9 MGOe to about 7.1 MGOe, from about 6.1 MGOe to about 7.1 MGOe, from about 6.2 MGOe to about 7.1 MGOe, from about 6.3 MGOe to about 7.1 MGOe, from about 6.4 MGOe to about 7.1 MGOe, from about 6.5 MGOe to about 7.1 MGOe, from about 6.7 MGOe to about 7.1 MGOe, from about 6.9 MGOe to about 7.1 MGOe, from about 5.5 MGOe to about 6.9 MGOe, from about 5.7 MGOe to about 6.9 MGOe, from about 5.9 MGOe to about 6.9 MGOe, from about 6.1 MGOe to about 6.9 MGOe, from about 6.2 MGOe to about 6.9 MGOe, from about 6.3 MGOe to about 6.9 MGOe, from about 6.4 MGOe to about 6.9 MGOe, from about 6.5 MGOe to about 6.9 MGOe, from about 6.7 MGOe to about 6.9 MGOe, from about 5.5 MGOe to about 6.7 MGOe, from about 5.7 MGOe to about 6.7 MGOe, from about 5.9 MGOe to about 6.7 MGOe, from about 6.1 MGOe to about 6.7 MGOe, from about 6.2 MGOe to about 6.7 MGOe, from about 6.3 MGOe to about 6.7 MGOe, from about 6.4 MGOe to about 6.7 MGOe, from about 6.5 MGOe to about 6.7 MGOe, from about 5.5 MGOe to about 6.5 MGOe, from about 5.7 MGOe to about 6.5 MGOe, from about 5.9 MGOe to about 6.5 MGOe, from about 6.1 MGOe to about 6.5 MGOe, from about 6.2 MGOe to about 6.5 MGOe, from about 6.3 MGOe to about 6.5 MGOe, from about 6.4 MGOe to about 6.5 MGOe, from about 5.5 MGOe to about 6.4 MGOe, from about 5.7 MGOe to about 6.4 MGOe, from about 5.9 MGOe to about 6.4 MGOe, from about 6.1 MGOe to about 6.4 MGOe, from about 6.2 MGOe to about 6.4 MGOe, from about 6.3 MGOe to about 6.4 MGOe, from about 5.5 MGOe to about 6.3 MGOe, from about 5.7 MGOe to about 6.3 MGOe, from about 5.9 MGOe to about 6.3 MGOe, from about 6.1 MGOe to about 6.3 MGOe, from about 6.2 MGOe to about 6.3 MGOe, from about 5.5 MGOe to about 6.2 MGOe, from about 5.7 MGOe to about 6.2 MGOe, from about 5.9 MGOe to about 6.2 MGOe, from about 6.1 MGOe to about 6.2 MGOe, from about 5.5 MGOe to about 6.1 MGOe, from about 5.7 MGOe to about 6.1 MGOe, from about 5.9 MGOe to about 6.1 MGOe, from about 5.5 MGOe to about 5.9 MGOe, from about 5.7 MGOe to about 5.9 MGOe, from about 5.5 MGOe to about 5.7 MGOe, or at most about 5.5 MGOe, at most about 5.7 MGOe, at most about 5.9 MGOe, at most about 6.1 MGOe, at most about 6.2 MGOe, at most about 6.3 MGOe, at most about 6.4 MGOe, at most about 6.5 MGOe, at most about 6.7 MGOe, at most about 6.9 MGOe, at most about 7.1 MGOe, at most about 7.3 MGOe, at most about 7.4 MGOe, at most about 7.5 MGOe, or about 5.5 MGOe, about 5.7 MGOe, about 5.9 MGOe, about 6.1 MGOe, about 6.2 MGOe, about 6.3 MGOe, about 6.4 MGOe, about 6.5 MGOe, about 6.7 MGOe, about 6.9 MGOe, about 7.1 MGOe, about 7.3 MGOe, about 7.4 MGOe, about 7.5 MGOe, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub -ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0109] The present invention also provides a bonded magnet comprising the magnetic powder as disclosed herein.

[0110] In some embodiments, the bonded magnet may be a compression-moulded (CM) magnet or an injection-moulded (IM) magnet. CM magnets may be produced by first mixing the magnetic powders with a polymer binder (usually 1- 3 wt.%) and lubricant, and then compressing the mixture in apress mould. The compressed mixture is then cured inside an oven to produce CM magnets.

[0111] IM magnets may be produced by first crushing the magnetic powders into about -80 mesh powders, then mixing the magnetic powders with a thermoplastic binder (usually about 7-13 wt.%), coupling agent, anti-oxidant and lubricants to form compound pellets using an extruder (such as a twin-screw extruder); then melting and injecting the compound pellets into a mould using an injection moulding machine.

[0112] In some embodiments, the disclosed CM bonded magnet may exhibit densities in a range of at least about 5.70 g / cc, at least about 5.80 g / cc, at least about 5.90 g / cc, at least about 5.97 g / cc, at least about 6.00 g / cc, at least about 6.01 g / cc, at least about 6.02 g / cc, at least about 6.04 g / cc, at least about 6.10 g / cc, at least about 6.20 g / cc, at least about 6.30 g / cc, or from about 5.70 g / cc to about 6.30 g / cc, from about 5.80 g / cc to about 6.30 g / cc, from about 5.90 g / cc to about 6.30 g / cc, from about 5.97 g / cc to about 6.30 g / cc, from about 6.00 g / cc to about 6.30 g / cc, from about 6.01 g / cc to about 6.30 g / cc, from about 6.02 g / cc to about 6.30 g / cc, from about 6.04 g / cc to about 6.30 g / cc. from about 6.10 g / cc to about 6.30 g / cc, from about 6.20 g / cc to about 6.30 g / cc, from about 5.70 g / cc to about 6.20 g / cc, from about 5.80 g / cc to about 6.20 g / cc, from about 5.90 g / cc to about 6.20 g / cc, from about 5.97 g / cc to about 6.20 g / cc, from about 6.00 g / cc to about 6.20 g / cc, from about 6.01 g / cc to about 6.20 g / cc, from about 6.02 g / cc to about 6.20 g / cc, from about 6.04 g / cc to about 6.20 g / cc, from about 6.10 g / cc to about 6.20 g / cc, from about 5.70 g / cc to about 6.10 g / cc, from about 5.80 g / cc to about 6.10 g / cc, from about 5.90 g / cc to about 6.10 g / cc, from about 5.97 g / cc to about 6.10 g / cc, from about 6.00 g / cc to about 6.10 g / cc, from about 6.01 g / cc to about 6.10 g / cc, from about 6.02 g / cc to about 6.10 g / cc, from about 6.04 g / cc to about 6.10 g / cc, from about 5.70 g / cc to about 6.04 g / cc, from about 5.80 g / cc to about 6.04 g / cc, from about 5.90 g / cc to about 6.04 g / cc, from about 5.97 g / cc to about 6.04 g / cc, from about 6.00 g / cc to about 6.04 g / cc, from about 6.01 g / cc to about 6.04 g / cc, from about 6.02 g / cc to about 6.04 g / cc, from about 5.70 g / cc to about 6.02 g / cc, from about 5.80 g / cc to about 6.02 g / cc, from about 5.90 g / cc to about 6.02 g / cc, from about 5.97 g / cc to about 6.02 g / cc, from about 6.00 g / cc to about 6.02 g / cc, from about 6.01 g / cc to about 6.02 g / cc, from about 5.70 g / cc to about 6.01 g / cc, from about 5.80 g / cc to about 6.01 g / cc, from about 5.90 g / cc to about 6.01 g / cc, from about 5.97 g / cc to about 6.01 g / cc, from about 6.00 g / cc to about 6.01 g / cc, from about 5.70 g / cc to about 6.00 g / cc, from about 5.80 g / cc to about 6.00 g / cc, from about 5.90 g / cc to about 6.00 g / cc, from about 5.97 g / cc to about 6.00 g / cc, from about 5.70 g / cc to about 5.97 g / cc, from about 5.80 g / cc to about 5.97 g / cc, from about 5.90 g / cc to about 5.97 g / cc, from about 5.70 g / cc to about 5.90 g / cc, from about

[0113] 5.80 g / cc to about 5.90 g / cc, from about 5.70 g / cc to about 5.80 g / cc, or at most about 5.70 g / cc, at most about 5.80 g / cc, at most about 5.90 g / cc, at most about 5.97 g / cc, at most about 6.00 g / cc, at most about 6.01 g / cc, at most about 6.02 g / cc, at most about 6.04 g / cc, at most about 6.10 g / cc, at most about 6.20 g / cc, at most about 6.30 g / cc, or about 5.70 g / cc, about 5.80 g / cc, about 5.90 g / cc, about 5.97 g / cc, about 6.00 g / cc, about 6.01 g / cc, about 6.02 g / cc, about 6.04 g / cc, about 6.10 g / cc, about 6.20 g / cc, about 6.30 g / cc, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0114] In some embodiments, the disclosed IM bonded magnet may exhibit densities in a range of at least about 4.30 g / cc, at least about 4.40 g / cc, at least about 4.50 g / cc, at least about 4.56 g / cc, at least about 4.60 g / cc, at least about 4.61 g / cc, at least about 4.64 g / cc, at least about 4.70 g / cc, at least about

[0115] 4.80 g / cc, at least about 4.90 g / cc, or from about 4.30 g / cc to about 4.90 g / cc, from about 4.40 g / cc to about 4.90 g / cc, from about 4.50 g / cc to about 4.90 g / cc, from about 4.56 g / cc to about 4.90 g / cc, from about 4.60 g / cc to about 4.90 g / cc, from about 4.61 g / cc to about 4.90 g / cc, from about 4.64 g / cc to about 4.90 g / cc, from about 4.70 g / cc to about 4.90 g / cc, from about 4.80 g / cc to about 4.90 g / cc, from about 4.30 g / cc to about 4.80 g / cc, from about 4.40 g / cc to about 4.80 g / cc, from about 4.50 g / cc to about 4.80 g / cc, from about 4.56 g / cc to about 4.80 g / cc, from about 4.60 g / cc to about 4.80 g / cc, from about 4.61 g / cc to about 4.80 g / cc, from about 4.64 g / cc to about 4.80 g / cc, from about 4.70 g / cc to about 4.80 g / cc, from about 4.30 g / cc to about 4.70 g / cc, from about 4.40 g / cc to about 4.70 g / cc, from about 4.50 g / cc to about 4.70 g / cc, from about 4.56 g / cc to about 4.70 g / cc, from about 4.60 g / cc to about 4.70 g / cc, from about 4.61 g / cc to about 4.70 g / cc, from about 4.64 g / cc to about 4.70 g / cc, from about 4.30 g / cc to about 4.64 g / cc, from about 4.40 g / cc to about 4.64 g / cc, from about 4.50 g / cc to about 4.64 g / cc, from about 4.56 g / cc to about 4.64 g / cc, from about 4.60 g / cc to about 4.64 g / cc, from about 4.61 g / cc to about 4.64 g / cc, from about 4.30 g / cc to about 4.61 g / cc, from about 4.40 g / cc to about 4.61 g / cc, from about 4.50 g / cc to about 4.61 g / cc, from about 4.56 g / cc to about 4.61 g / cc, from about 4.60 g / cc to about 4.61 g / cc, from about 4.30 g / cc to about 4.60 g / cc, from about 4.40 g / cc to about 4.60 g / cc, from about 4.50 g / cc to about 4.60 g / cc, from about 4.56 g / cc to about 4.60 g / cc, from about 4.30 g / cc to about 4.56 g / cc, from about 4.40 g / cc to about 4.56 g / cc, from about 4.50 g / cc to about 4.56 g / cc, from about 4.30 g / cc to about 4.50 g / cc, from about 4.40 g / cc to about 4.50 g / cc, from about 4.30 g / cc to about 4.40 g / cc, or at most about 4.30 g / cc, at most about 4.40 g / cc, at most about 4.50 g / cc, at most about 4.56 g / cc, at most about 4.60 g / cc, at most about 4.61 g / cc, at most about 4.64 g / cc, at most about 4.70 g / cc, at most about 4.80 g / cc, at most about 4.90 g / cc, or about 4.30 g / cc, about 4.40 g / cc, about 4.50 g / cc, about 4.56 g / cc, about 4.60 g / cc, about 4.61 g / cc, about 4.64 g / cc, about 4.70 g / cc, about 4.80 g / cc, about 4.90 g / cc, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub -ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0116] In some embodiments, the CM bonded magnet may exhibit remanence (Br) values in a range of at least about 4.00 kG, at least about 4.20 kG, at least about 4.40 kG, at least about 4.60 kG, at least about 4.63 kG, at least about 4.69 kG, at least about 4.70 kG, at least about 4.80 kG, at least about 4.84 kG, at least about 4.89 kG, at least about 5.00 kG, at least about 5.20 kG, or from about 4.00 kG to about 5.20 kG, from about 4.20 kG to about 5.20 kG, from about 4.40 kG to about 5.20 kG, from about 4.60 kG to about 5.20 kG, from about 4.63 kG to about 5.20 kG, from about 4.69 kG to about 5.20 kG, from about 4.70 kG to about 5.20 kG, from about 4.80 kG to about 5.20 kG, from about 4.84 kG to about 5.20 kG, from about 4.89 kG to about 5.20 kG, from about 5.00 kG to about 5.20 kG, from about 4.00 kG to about 5.00 kG, from about 4.20 kG to about 5.00 kG, from about 4.40 kG to about 5.00 kG, from about 4.60 kG to about 5.00 kG, from about 4.63 kG to about 5.00 kG, from about 4.69 kG to about 5.00 kG, from about 4.70 kG to about 5.00 kG, from about 4.80 kG to about 5.00 kG, from about 4.84 kG to about 5.00 kG, from about 4.89 kG to about 5.00 kG, from about 4.00 kG to about 4.89 kG, from about 4.20 kG to about 4.89 kG, from about 4.40 kG to about 4.89 kG, from about 4.60 kG to about 4.89 kG, from about 4.63 kG to about 4.89 kG, from about 4.69 kG to about 4.89 kG, from about 4.70 kG to about 4.89 kG, from about 4.80 kG to about 4.89 kG, from about 4.84 kG to about 4.89 kG, from about 4.00 kG to about 4.84 kG, from about 4.20 kG to about 4.84 kG, from about 4.40 kG to about 4.84 kG, from about 4.60 kG to about 4.84 kG, from about 4.63 kG to about 4.84 kG, from about 4.69 kG to about 4.84 kG, from about 4.70 kG to about 4.84 kG, from about 4.80 kG to about 4.84 kG, from about 4.00 kG to about 4.80 kG, from about 4.20 kG to about 4.80 kG, from about 4.40 kG to about 4.80 kG, from about 4.60 kG to about 4.80 kG, from about 4.63 kG to about 4.80 kG, from about 4.69 kG to about 4.80 kG, from about 4.70 kG to about 4.80 kG, from about 4.00 kG to about 4.70 kG, from about 4.20 kG to about 4.70 kG, from about 4.40 kG to about 4.70 kG, from about 4.60 kG to about 4.70 kG, from about 4.63 kG to about 4.70 kG, from about 4.69 kG to about 4.70 kG, from about 4.00 kG to about 4.69 kG, from about 4.20 kG to about 4.69 kG, from about 4.40 kG to about 4.69 kG, from about 4.60 kG to about 4.69 kG, from about 4.63 kG to about 4.69 kG, from about 4.00 kG to about 4.63 kG, from about 4.20 kG to about 4.63 kG, from about 4.40 kG to about 4.63 kG, from about 4.60 kG to about 4.63 kG, from about 4.00 kG to about 4.60 kG, from about 4.20 kG to about 4.60 kG, from about 4.40 kG to about 4.60 kG, from about 4.00 kG to about 4.40 kG, from about 4.20 kG to about 4.40 kG, from about 4.00 kG to about 4.20 kG, or at most about 4.00 kG, at most about 4.20 kG, at most about 4.40 kG, at most about

[0117] 4.60 kG, at most about 4.63 kG, at most about 4.69 kG, at most about 4.70 kG, at most about 4.80 kG, at most about 4.84 kG, at most about 4.89 kG, at most about 5.00 kG, at most about 5.20 kG, or about 4.00 kG, about 4.20 kG, about 4.40 kG, about 4.60 kG, about 4.63 kG, about 4.69 kG, about 4.70 kG, about 4.80 kG, about 4.84 kG, about 4.89 kG, about 5.00 kG, about 5.20 kG, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that arc within the stated range(s).

[0118] In some embodiments, the IM bonded magnet may exhibit remanence (Br) values in a range of at least about 2.80 kG, at least about 3.00 kG, at least about 3.20 kG, at least about 3.26 kG, at least about 3.33 kG, at least about 3.40 kG, at least about 3.53 kG, at least about 3.60 kG, at least about 3.80 kG, at least about 4.00 kG, or from about 2.80 kG to about 4.00 kG, from about 3.00 kG to about 4.00 kG, from about 3.20 kG to about 4.00 kG, from about 3.26 kG to about 4.00 kG, from about 3.33 kG to about 4.00 kG, from about 3.40 kG to about 4.00 kG, from about 3.53 kG to about 4.00 kG, from about 3.60 kG to about 4.00 kG, from about 3.80 kG to about 4.00 kG, from about 2.80 kG to about 3.80 kG, from about 3.00 kG to about 3.80 kG, from about 3.20 kG to about 3.80 kG, from about 3.26 kG to about 3.80 kG, from about 3.33 kG to about 3.80 kG, from about 3.40 kG to about 3.80 kG, from about 3.60 kG to about 3.80 kG, from about 2.80 kG to about 3.60 kG, from about 3.00 kG to about 3.60 kG, from about 3.20 kG to about 3.60 kG, from about 3.26 kG to about 3.60 kG, from about 3.33 kG to about 3.60 kG, from about 3.40 kG to about 3.60 kG, from about 3.53 kG to about 3.60 kG, from about 2.80 kG to about 3.53 kG, from about 3.00 kG to about 3.53 kG, from about 3.20 kG to about 3.53 kG, from about 3.26 kG to about 3.53 kG, from about 3.33 kG to about 3.53 kG, from about 3.40 kG to about 3.53 kG, from about 2.80 kG to about 3.40 kG, from about 3.00 kG to about 3.40 kG, from about 3.20 kG to about 3.40 kG, from about 3.26 kG to about 3.40 kG, from about 3.33 kG to about 3.40 kG, from about 2.80 kG to about 3.33 kG, from about 3.00 kG to about 3.33 kG, from about 3.20 kG to about 3.33 kG, from about 3.26 kG to about 3.33 kG, from about 2.80 kG to about 3.26 kG, from about 3.00 kG to about 3.26 kG, from about 3.20 kG to about 3.26 kG, from about 2.80 kG to about 3.20 kG, from about 3.00 kG to about 3.20 kG, from about 2.80 kG to about 3.00 kG, or at most about 2.80 kG, at most about 3.00 kG, at most about 3.20 kG, at most about 3.26 kG, at most about 3.33 kG, at most about 3.40 kG, at most about 3.53 kG, at most about

[0119] 3.60 kG, at most about 3.80 kG, at most about 4.00 kG, or about 2.80 kG, about 3.00 kG, about 3.20 kG, about 3.26 kG, about 3.33 kG, about 3.40 kG, about 3.53 kG, about 3.60 kG, about 3.80 kG, about 4.00 kG, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0120] In some embodiments, the CM bonded magnet may exhibit intrinsic coercivity (HCi) values in a range of at least about 3.5 kOe, at least about 3.9 kOe, at least about 4.0 kOe, at least about 4.5 kOe, at least about 4.9 kOe, at least about 5.0 kOe, at least about 5.1 kOe, at least about 5.5 kOe, at least about 6.0 kOe, at least about 6.5 kOe, at least about 7.0 kOe, or from about 3.5 kOe to about 7.0 kOe, from about 3.9 kOe to about 7.0 kOe, from about 4.0 kOe to about 7.0 kOe, from about 4.5 kOc to about 7.0 kOe, from about 4.9 kOe to about 7.0 kOe, from about 5.0 kOe to about 7.0 kOe, from about 5.1 kOe to about 7.0 kOe, from about 5.5 kOe to about 7.0 kOe, from about 6.0 kOe to about 7.0 kOe, from about 6.5 kOe to about 7.0 kOe, from about 3.5 kOe to about 6.5 kOe, from about 3.9 kOe to about 6.5 kOe, from about 4.0 kOe to about 6.5 kOe, from about 4.5 kOe to about 6.5 kOe, from about 4.9 kOe to about 6.5 kOe, from about 5.0 kOe to about 6.5 kOe, from about 5.1 kOe to about 6.5 kOe, from about 5.5 kOe to about 6.5 kOe, from about 6.0 kOe to about 6.5 kOe, from about 3.5 kOe to about 6.0 kOe, from about 3.9 kOe to about 6.0 kOe, from about 4.0 kOe to about 6.0 kOe, from about 4.5 kOe to about 6.0 kOe, from about 4.9 kOe to about 6.0 kOe, from about 5.0 kOe to about 6.0 kOe, from about 5.1 kOc to about 6.0 kOe, from about 5.5 kOe to about 6.0 kOc, from about 3.5 kOc to about 5.5 kOe, from about 3.9 kOe to about 5.5 kOe, from about 4.0 kOe to about 5.5 kOe, from about

[0121] 4.5 kOe to about 5.5 kOe, from about 4.9 kOe to about 5.5 kOe, from about 5.0 kOe to about 5.5 kOe, from about 5.1 kOe to about 5.5 kOe, from about 3.5 kOe to about 5.1 kOe, from about 3.9 kOe to about 5.1 kOe, from about 4.0 kOe to about 5.1 kOe, from about 4.5 kOe to about 5.1 kOe, from about

[0122] 4.9 kOe to about 5.1 kOe, from about 5.0 kOe to about 5.1 kOe, from about 3.5 kOe to about 5.0 kOe, from about 3.9 kOc to about 5.0 kOc, from about 4.0 kOc to about 5.0 kOc, from about 4.5 kOc to about 5.0 kOe, from about 4.9 kOe to about 5.0 kOe, from about 3.5 kOe to about 4.9 kOe, from about

[0123] 3.9 kOe to about 4.9 kOe, from about 4.0 kOe to about 4.9 kOe, from about 4.5 kOe to about 4.9 kOe, from about 3.5 kOe to about 4.5 kOe, from about 3.9 kOe to about 4.5 kOe, from about 4.0 kOe to about 4.5 kOc, from about 3.5 kOc to about 4.0 kOc, from about 3.9 kOc to about 4.0 kOc, from about

[0124] 3.5 kOe to about 3.9 kOe, or at most about 3.5 kOe, at most about 3.9 kOe, at most about 4.0 kOe, at most about 4.5 kOe, at most about 4.9 kOe, at most about 5.0 kOe, at most about 5.1 kOe, at most about 5.5 kOe, at most about 6.0 kOe, at most about 6.5 kOe, at most about 7.0 kOe, or about 3.5 kOe, about 3.9 kOe, about 4.0 kOe, about 4.5 kOe, about 4.9 kOe, about 5.0 kOe, about 5.1 kOe, about 5.5 kOe, about 6.0 kOe, about 6.5 kOe, about 7.0 kOe, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub -ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0125] In some embodiments, the CM bonded magnet may exhibit normal coercivity (Hc) values in a range of at least about 2.9 kOe, at least about 3.0 kOe, at least about 3.1 kOe, at least about 3.2 kOe, at least about 3.3 kOc, at least about 3.4 kOc, at least about 3.5 kOe, at least about 3.6 kOc, at least about 3.7 kOe, at least about 3.8 kOe, or from about 2.9 kOe to about 3.8 kOe, from about 3.0 kOe to about 3.8 kOe, from about 3.1 kOe to about 3.8 kOe, from about 3.2 kOe to about 3.8 kOe, from about 3.3 kOe to about 3.8 kOe, from about 3.4 kOe to about 3.8 kOe, from about 3.5 kOe to about 3.8 kOe, from about 3.6 kOe to about 3.8 kOe, from about 3.7 kOe to about 3.8 kOe, from about 2.9 kOe to about 3.7 kOe, from about 3.0 kOe to about 3.7 kOe, from about 3.1 kOe to about 3.7 kOe, from about 3.2 kOe to about 3.7 kOe, from about 3.3 kOe to about 3.7 kOe, from about 3.4 kOe to about 3.7 kOe, from about 3.5 kOe to about 3.7 kOe, from about 3.6 kOe to about 3.7 kOe, from about 2.9 kOe to about 3.6 kOe, from about 3.0 kOe to about 3.6 kOe, from about 3.1 kOe to about 3.6 kOe, from about

[0126] 3.2 kOe to about 3.6 kOe, from about 3.3 kOe to about 3.6 kOe, from about 3.4 kOe to about 3.6 kOe, from about 3.5 kOc to about 3.6 kOc, from about 2.9 kOc to about 3.5 kOc, from about 3.0 kOc to about 3.5 kOe, from about 3.1 kOe to about 3.5 kOe, from about 3.2 kOe to about 3.5 kOe, from about

[0127] 3.3 kOe to about 3.5 kOe, from about 3.4 kOe to about 3.5 kOe, from about 2.9 kOe to about 3.4 kOe, from about 3.0 kOe to about 3.4 kOe, from about 3.1 kOe to about 3.4 kOe, from about 3.2 kOe to about 3.4 kOe, from about 3.3 kOe to about 3.4 kOe, from about 2.9 kOe to about 3.3 kOe, from about 3.0 kOc to about 3.3 kOc, from about 3.1 kOc to about 3.3 kOc, from about 3.2 kOc to about 3.3 kOc, from about 2.9 kOe to about 3.2 kOe, from about 3.0 kOe to about 3.2 kOe, from about 3.1 kOe to about 3.2 kOe, from about 2.9 kOe to about 3.1 kOe, from about 3.0 kOe to about 3.1 kOe, from about

[0128] 2.9 kOe to about 3.0 kOe, or at most about 2.9 kOe, at most about 3.0 kOe, at most about 3. 1 kOe, at most about 3.2 kOe, at most about 3.3 kOe, at most about 3.4 kOe, at most about 3.5 kOe, at most about 3.6 kOc, at most about 3.7 kOc, at most about 3.8 kOe, or about 2.9 kOe, about 3.0 kOc, about 3.1 kOe, about 3.2 kOe, about 3.3 kOe, about 3.4 kOe, about 3.5 kOe, about 3.6 kOe, about 3.7 kOe, about 3.8 kOe, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0129] In some embodiments, the IM bonded magnet may exhibit intrinsic coercivity (Ha) values in a range of at least about 3.5 kOe, at least about 3.9 kOe, at least about 4.0 kOe, at least about 4.5 kOe, at least about 4.8 kOe, at least about 5.0 kOe, at least about 5.1 kOe, at least about 5.5 kOe, at least about 6.0 kOe, at least about 6.5 kOe, at least about 7.0 kOe, or from about 3.5 kOe to about 7.0 kOe, from about 3.9 kOe to about 7.0 kOe, from about 4.0 kOe to about 7.0 kOe, from about 4.5 kOe to about 7.0 kOe, from about 4.8 kOe to about 7.0 kOe, from about 5.0 kOe to about 7.0 kOe, from about

[0130] 5.1 kOe to about 7.0 kOe, from about 5.5 kOe to about 7.0 kOe, from about 6.0 kOe to about 7.0 kOe, from about 6.5 kOe to about 7.0 kOe, from about 3.5 kOe to about 6.5 kOe, from about 3.9 kOe to about 6.5 kOe, from about 4.0 kOe to about 6.5 kOe, from about 4.5 kOe to about 6.5 kOe, from about 4.8 kOe to about 6.5 kOe, from about 5.0 kOe to about 6.5 kOe, from about 5.1 kOe to about 6.5 kOe, from about 5.5 kOe to about 6.5 kOe, from about 6.0 kOe to about 6.5 kOe, or from about 3.5 kOe to about 6.0 kOe, from about 3.9 kOe to about 6.0 kOe, from about 4.0 kOe to about 6.0 kOe, from about 4.5 kOe to about 6.0 kOe, from about 4.8 kOe to about 6.0 kOe, from about 5.0 kOe to about 6.0 kOe, from about 5.1 kOe to about 6.0 kOe, from about 5.5 kOe to about 6.0 kOe, from about 3.5 kOe to about 5.5 kOe, from about 3.9 kOe to about 5.5 kOe, from about 4.0 kOe to about 5.5 kOe, from about

[0131] 4.5 kOe to about 5.5 kOe, from about 4.8 kOe to about 5.5 kOe, from about 5.0 kOe to about 5.5 kOe, from about 5.1 kOe to about 5.5 kOe, from about 3.5 kOe to about 5.1 kOe, from about 3.9 kOe to about 5.1 kOe, from about 4.0 kOe to about 5.1 kOe, from about 4.5 kOe to about 5.1 kOe, from about

[0132] 4.8 kOe to about 5.1 kOe, from about 5.0 kOe to about 5.1 kOe, from about 3.5 kOe to about 5.0 kOe, from about 3.9 kOe to about 5.0 kOe, from about 4.0 kOe to about 5.0 kOe, from about 4.5 kOe to about 5.0 kOe, from about 4.8 kOe to about 5.0 kOe, from about 3.5 kOe to about 4.8 kOe, from about

[0133] 3.9 kOe to about 4.8 kOe, from about 4.0 kOe to about 4.8 kOe, from about 4.5 kOe to about 4.8 kOe, from about 3.5 kOe to about 4.5 kOe, from about 3.9 kOe to about 4.5 kOe, from about 4.0 kOe to about 4.5 kOe, from about 3.5 kOe to about 4.0 kOe, from about 3.9 kOe to about 4.0 kOe, from about

[0134] 3.5 kOe to about 3.9 kOe, or at most about 3.5 kOe, at most about 3.9 kOe, at most about 4.0 kOe, at most about 4.5 kOe, at most about 4.8 kOe, at most about 5.0 kOe, at most about 5.1 kOe, at most about 5.5 kOe, at most about 6.0 kOe, at most about 6.5 kOe, at most about 7.0 kOe, or about 3.5 kOe, about 3.9 kOe, about 4.0 kOe, about 4.5 kOe, about 4.8 kOe, about 5.0 kOe, about 5.1 kOe, about 5.5 kOe, about 6.0 kOe, about 6.5 kOe, about 7.0 kOe, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub -ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0135] In some embodiments, the IM bonded magnet may exhibit normal coercivity (Hc) values in a range of at least about 2.5 kOe, at least about 2.6 kOe, at least about 2.7 kOe, at least about 2.8 kOe, at least about 2.9 kOe, at least about 3.0 kOe, at least about 3.1 kOe, at least about 3.2 kOe, at least about 3.3 kOe, at least about 3.4 kOe, at least about 3.5 kOe, or from about 2.5 kOe to about 3.5 kOe, from about 2.6 kOe to about 3.5 kOe, from about 2.7 kOe to about 3.5 kOe, from about 2.8 kOe to about 3.5 kOe, from about 2.9 kOe to about 3.5 kOe, from about 3.0 kOe to about 3.5 kOe, from about

[0136] 3.1 kOe to about 3.5 kOe, from about 3.2 kOe to about 3.5 kOe, from about 3.3 kOe to about 3.5 kOe, from about 3.4 kOe to about 3.5 kOe, from about 2.5 kOe to about 3.4 kOe, from about 2.6 kOe to about 3.4 kOe, from about 2.7 kOe to about 3.4 kOe, from about 2.8 kOe to about 3.4 kOe, from about

[0137] 2.9 kOe to about 3.4 kOe, from about 3.0 kOe to about 3.4 kOe, from about 3.1 kOe to about 3.4 kOe, from about 3.2 kOe to about 3.4 kOe, from about 3.3 kOe to about 3.4 kOe, from about 2.5 kOe to about 3.3 kOe, from about 2.6 kOe to about 3.3 kOe, from about 2.7 kOe to about 3.3 kOe, from about 2.8 kOe to about 3.3 kOe, from about 2.9 kOe to about 3.3 kOe, from about 3.0 kOe to about 3.3 kOe, from about 3.1 kOe to about 3.3 kOe, from about 3.2 kOe to about 3.3 kOe, from about 2.5 kOe to about 3.2 kOe, from about 2.6 kOe to about 3.2 kOe, from about 2.7 kOe to about 3.2 kOe, from about

[0138] 2.8 kOe to about 3.2 kOe, from about 2.9 kOe to about 3.2 kOe, from about 3.0 kOe to about 3.2 kOe, from about 3.1 kOe to about 3.2 kOe, from about 2.5 kOe to about 3.1 kOe, from about 2.6 kOe to about 3.1 kOe, from about 2.7 kOe to about 3.1 kOe, from about 2.8 kOe to about 3.1 kOe, from about

[0139] 2.9 kOe to about 3.1 kOe, from about 3.0 kOe to about 3.1 kOe, from about 2.5 kOe to about 3.0 kOe, from about 2.6 kOe to about 3.0 kOe, from about 2.7 kOe to about 3.0 kOe, from about 2.8 kOe to about 3.0 kOe, from about 2.9 kOe to about 3.0 kOe, from about 2.5 kOe to about 2.9 kOe, from about 2.6 kOc to about 2.9 kOc, from about 2.7 kOc to about 2.9 kOc, from about 2.8 kOe to about 2.9 kOc, from about 2.5 kOe to about 2.8 kOe, from about 2.6 kOe to about 2.8 kOe, from about 2.7 kOe to about 2.8 kOe, from about 2.5 kOe to about 2.7 kOe, from about 2.6 kOe to about 2.7 kOe, from about

[0140] 2.5 kOe to about 2.6 kOe, or at most about 2.5 kOe, at most about 2.6 kOe, at most about 2.7 kOe, at most about 2.8 kOe, at most about 2.9 kOe, at most about 3.0 kOe, at most about 3.1 kOe, at most about 3.2 kOe, at most about 3.3 kOe, at most about 3.4 kOe, at most about 3.5 kOe, or about 2.5 kOc, about 2.6 kOc, about 2.7 kOc, about 2.8 kOc, about 2.9 kOc, about 3.0 kOc, about 3.1 kOc, about 3.2 kOe, about 3.3 kOe, about 3.4 kOe, about 3.5 kOe, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub -ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0141] In some embodiments, the CM bonded magnet may exhibit maximum energy product ((BH)max) values in a range of at least about 3.5 MGOe, at least about 3.6 MGOe, at least about 3.7 MGOe, at least about 3.8 MGOe, at least about 3.9 MGOe, at least about 4.0 MGOe, at least about 4.1 MGOe, at least about 4.2 MGOe, at least about 4.3 MGOe, at least about 4.4 MGOe, at least about

[0142] 4.5 MGOe, at least about 4.6 MGOe, at least about 4.7 MGOe, or from about 3.5 MGOe to about 4.7 MGOe, from about 3.6 MGOe to about 4.7 MGOe, from about 3.7 MGOe to about 4.7 MGOe, from about 3.8 MGOe to about 4.7 MGOe, from about 3.9 MGOe to about 4.7 MGOe, from about 4.0 MGOe to about 4.7 MGOe, from about 4.1 MGOe to about 4.7 MGOe, from about 4.2 MGOe to about 4.7 MGOe, from about 4.3 MGOe to about 4.7 MGOe, from about 4.4 MGOe to about 4.7 MGOe, from about 4.5 MGOe to about 4.7 MGOe, from about 4.6 MGOe to about 4.7 MGOe, from about 3.5 MGOe to about 4.6 MGOe, from about 3.6 MGOe to about 4.6 MGOe, from about 3.7 MGOe to about 4.6 MGOe, from about 3.8 MGOe to about 4.6 MGOe, from about 3.9 MGOe to about 4.6 MGOe, from about 4.0 MGOe to about 4.6 MGOe, from about 4.1 MGOe to about 4.6 MGOe, from about 4.2 MGOe to about 4.6 MGOe, from about 4.3 MGOe to about 4.6 MGOe, from about 4.4 MGOe to about 4.6 MGOe, from about 4.5 MGOe to about 4.6 MGOe, from about 3.5 MGOe to about 4.5 MGOe, from about 3.6 MGOe to about 4.5 MGOe, from about 3.7 MGOe to about 4.5 MGOe, from about 3.8 MGOe to about 4.5 MGOe, from about 3.9 MGOe to about 4.5 MGOe, from about 4.0 MGOe to about 4.5 MGOe, from about 4.1 MGOe to about 4.5 MGOe, from about 4.2 MGOe to about 4.5 MGOe, from about 4.3 MGOe to about 4.5 MGOe, from about 4.4 MGOe to about 4.5 MGOe, from about 3.5 MGOe to about 4.4 MGOe, from about 3.6 MGOe to about 4.4 MGOe, from about 3.7 MGOe to about 4.4 MGOe, from about 3.8 MGOe to about 4.4 MGOe, from about 3.9 MGOe to about 4.4 MGOe, from about 4.0 MGOe to about 4.4 MGOe, from about 4.1 MGOe to about 4.4 MGOe, from about 4.2 MGOe to about 4.4 MGOe, from about 4.3 MGOe to about 4.4 MGOe, from about 3.5 MGOe to about 4.3 MGOe, from about 3.6 MGOe to about 4.3 MGOe, from about 3.7 MGOe to about 4.3 MGOe, from about 3.8 MGOe to about 4.3 MGOe, from about 3.9 MGOe to about 4.3 MGOe, from about 4.0 MGOe to about 4.3 MGOe, from about 4.1 MGOe to about 4.3 MGOe, from about 4.2 MGOe to about 4.3 MGOe, from about 3.5 MGOe to about 4.2 MGOe, from about 3.6 MGOe to about 4.2 MGOe, from about 3.7 MGOe to about 4.2 MGOe, from about 3.8 MGOe to about 4.2 MGOe, from about 3.9 MGOe to about 4.2 MGOe, from about 4.0 MGOe to about 4.2 MGOe, from about 4.1 MGOe to about 4.2 MGOe, from about 3.5 MGOe to about 4.1 MGOe, from about 3.6 MGOe to about 4.1 MGOe, from about 3.7 MGOe to about 4.1 MGOe, from about 3.8 MGOe to about 4.1 MGOe, from about 3.9 MGOe to about 4.1 MGOe, from about 4.0 MGOe to about 4.1 MGOe, from about 3.5 MGOe to about 4.0 MGOe, from about 3.6 MGOe to about 4.0 MGOe, from about 3.7 MGOe to about 4.0 MGOe, from about 3.8 MGOe to about 4.0 MGOe, from about 3.9 MGOe to about 4.0 MGOe, from about 3.5 MGOe to about 3.9 MGOe, from about 3.6 MGOe to about 3.9 MGOe, from about 3.7 MGOe to about 3.9 MGOe, from about 3.8 MGOe to about 3.9 MGOe, from about 3.5 MGOe to about 3.8 MGOe, from about 3.6 MGOe to about 3.8 MGOe, from about 3.7 MGOe to about 3.8 MGOe, from about 3.5 MGOe to about 3.7 MGOe, from about 3.6 MGOe to about 3.7 MGOe, from about 3.5 MGOc to about 3.6 MGOe, or at most about 3.5 MGOe, at most about 3.6 MGOe, at most about 3.7 MGOe, at most about 3.8 MGOe, at most about 3.9 MGOe, at most about 4.0 MGOe, at most about

[0143] 4.1 MGOe, at most about 4.2 MGOe, at most about 4.3 MGOe, at most about 4.4 MGOe, at most about 4.5 MGOe, at most about 4.6 MGOe, at most about 4.7 MGOe, or about 3.5 MGOe, about 3.6 MGOe, about 3.7 MGOe, about 3.8 MGOe, about 3.9 MGOe, about 4.0 MGOe, about 4.1 MGOe, about 4.2 MGOe, about 4.3 MGOe, about 4.4 MGOe, about 4.5 MGOe, about 4.6 MGOe, about 4.7 MGOc, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0144] In some embodiments, the IM bonded magnet may exhibit maximum energy product ((BH)max) values in a range of at least about 1.8 MGOe, at least about 1.9 MGOe, at least about 2.0 MGOe, at least about 2.1 MGOe, at least about 2.2 MGOe, at least about 2.3 MGOe, at least about 2.4 MGOe, at least about 2.5 MGOe, at least about 2.6 MGOe, at least about 2.7 MGOe, at least about 2.8 MGOe, or from about 1.8 MGOe to about 2.8 MGOe, from about 1.9 MGOe to about 2.8 MGOe, from about 2.0 MGOe to about 2.8 MGOe, from about 2.1 MGOe to about 2.8 MGOe, from about

[0145] 2.2 MGOe to about 2.8 MGOe, from about 2.3 MGOe to about 2.8 MGOe, from about 2.4 MGOe to about 2.8 MGOe, from about 2.5 MGOe to about 2.8 MGOe, from about 2.6 MGOe to about 2.8 MGOe, from about 2.7 MGOe to about 2.8 MGOe, from about 1.8 MGOe to about 2.7 MGOe, from about 1.9 MGOe to about 2.7 MGOe, from about 2.0 MGOe to about 2.7 MGOe, from about 2.1 MGOe to about 2.7 MGOe, from about 2.2 MGOe to about 2.7 MGOe, from about 2.3 MGOe to about 2.7 MGOc, from about 2.4 MGOc to about 2.7 MGOc, from about 2.5 MGOc to about 2.7 MGOe, from about 2.6 MGOe to about 2.7 MGOe, from about 1.8 MGOe to about 2.6 MGOe, from about 1.9 MGOe to about 2.6 MGOe, from about 2.0 MGOe to about 2.6 MGOe, from about 2.1 MGOe to about 2.6 MGOe, from about 2.2 MGOe to about 2.6 MGOe, from about 2.3 MGOe to about 2.6 MGOe, from about 2.4 MGOe to about 2.6 MGOe, from about 2.5 MGOe to about 2.6 MGOe, from about 1.8 MGOe to about 2.5 MGOe, from about 1.9 MGOe to about 2.5 MGOe, from about 2.0 MGOe to about 2.5 MGOe, from about 2.1 MGOe to about 2.5 MGOe, from about 2.2 MGOe to about 2.5 MGOe, from about 2.3 MGOe to about 2.5 MGOe, from about 2.4 MGOe to about 2.5 MGOe, from about 1.8 MGOe to about 2.4 MGOe, from about 1.9 MGOe to about 2.4 MGOe, from about 2.0 MGOe to about 2.4 MGOe, from about 2.1 MGOe to about 2.4 MGOe, from about 2.2 MGOc to about 2.4 MGOc, from about 2.3 MGOc to about 2.4 MGOc, from about 1.8 MGOe to about 2.3 MGOe, from about 1.9 MGOe to about 2.3 MGOe, from about 2.0 MGOe to about 2.3 MGOe, from about 2.1 MGOe to about 2.3 MGOe, from about 2.2 MGOe to about 2.3 MGOe, from about 1.8 MGOe to about 2.2 MGOe, from about 1.9 MGOe to about 2.2 MGOe, from about 2.0 MGOe to about 2.2 MGOe, from about 2.1 MGOe to about 2.2 MGOe, from about 1.8 MGOc to about 2.1 MGOc, from about 1.9 MGOc to about 2.1 MGOc, from about 2.0 MGOc to about 2.1 MGOe, from about 1.8 MGOe to about 2.0 MGOe, from about 1.9 MGOe to about 2.0 MGOe, from about 1.8 MGOe to about 1.9 MGOe, or at most about 1.8 MGOe, at most about 1.9 MGOe, at most about 2.0 MGOe, at most about 2.1 MGOe, at most about 2.2 MGOe, at most about

[0146] 2.3 MGOe, at most about 2.4 MGOe, at most about 2.5 MGOe, at most about 2.6 MGOe, at most about 2.7 MGOc, at most about 2.8 MGOc, or about 1.8 MGOc, about 1.9 MGOc, about 2.0 MGOc, about 2.1 MGOe, about 2.2 MGOe, about 2.3 MGOe, about 2.4 MGOe, about 2.5 MGOe, about 2.6 MGOe, about 2.7 MGOe, about 2.8 MGOe, or any value or range therein. It is to be appreciated that the above ranges should be interpreted as including and supporting any sub-ranges or discrete values (which may or may not be a whole number) that are within the stated range(s).

[0147] The inventors have further surprisingly found that the inclusion of zirconium in the alloy composition results in the disclosed magnetic powders and bonded magnets exhibiting improved quench stability, advantageously resulting in more stable and repeatable magnetic properties in broader processing range, and making it suitable for robust mass production.

[0148] The inventors have further surprisingly found that the disclosed magnetic powders may exhibit improved magnetizing ability by requiring a lower magnetizing field strength for full magnetic saturation.

[0149] Exemplary, non-limiting embodiments of the disclosed magnetic powders and bonded magnets will now be disclosed.

[0150] Examples

[0151] Non-limiting examples of the invention and comparative examples will be further described in greater detail by reference to specific examples, which should not be construed as in any way limiting the scope of the invention.

[0152] Example 1: General method for preparing magnetic powders

[0153] A rapidly solidified alloy of composition was prepared by weighing the appropriate amount of raw material ng to the composition formula with a total weight of 100 grams, placing all the raw materials into an arc-melter, melting the respective raw materials under argon atmosphere and cooling it to obtain ingots. 1% extra amount of Cc and La was added prior to melting to compensate for the melting loss. The alloy ingots were flipped and re-melted four times to ensure homogeneity.

[0154] The ingots were then broken into pieces and loaded into a crucible tube with a small nozzle underneath and placed into a melt-spinner. The alloy ingots were heated up and re-melted in argon atmosphere and ejected onto a rotating metal wheel to form ribbons. The ejection temperature was about 1400 °C to 1600 °C, the ejection pressure was about 200 torr to 500 torr, the nozzle size was about 0.5mm to 1 ,4mm, and the wheel speed was about 10 m / s to 30 m / s, or about 15 m / s to 22 m / s. The ribbons were crushed to -40 mesh powder by a twin-roller crusher.

[0155] Magnetic powders of composition ( in a and (Ceo.sLao.zjisFeys.gBe.i were also prepared in a similar way as described above as control experiments.

[0156] Thereafter, the magnetic properties of the magnetic powders were measured with a Lakeshore vibrating sample magnetometer (VSM) (Table 1). Powders were pressed into a sample holder and magnetized by a 40 kOe peak pulse field prior to the VSM measurement. The second quadrant demagnetization curves were then measured by VSM with an applied field up to 20 kOe. A demagnetization factor of 0.21 was used to correct the demagnetization curves. The grain sizes of the magnetic powder were calculated from analysis of its X-ray diffraction (XRD) pattern (Fig. 1, Tabic 2). Powders were loaded onto a sample holder and pressed by a microscope slide to ensure a flat surface. Typical XRD spectra were obtained by scanning the sample in the range 30° < 20 < 50° by a PANalytical Empyrean X-ray Diffractometer. The grain sizes were calculated from XRD data where K is a dimensionless shape factor, and has a typical value of about 0.9; is the X-ray wavelength and has a value of 1.5405 A for Cu Ka as the X-ray source; p is the peak full width at half maximum (FWHM) in radians; and 0 is the Bragg angle.

[0157] Table 1: Characterization data of magnetic powders

[0158] Composition (at.%) BrHciHc(BH)maxGrain

[0159] (kG) (kOe) (kOe) (MGOe) size (nm)

[0160] From Table 1, it is shown that it is possible to produce CeLa-Fe-Zr-B (free of Nd and / or Pr) magnetic powders with useful magnetic properties. Further, it is shown that the remanence value (Br) of the magnetic powders increase as the amount of lanthanum used in the composition increases. Similarly, as the amount of zirconium used in the composition increases, the remanence value (Br) of the magnetic powders increases. This suggests that both lanthanum and zirconium contribute to a stronger magnetic flux density of the magnetic powders.

[0161] Additionally, Table 1 shows that the intrinsic coercivity (HCi) and normal coercivity (Hc) of the magnetic powders peak when the La / (La+Ce) ratio is 0.1. At the same time, the intrinsic coercivity (Hep and normal coercivity (Hc) of the magnetic powders decrease as the amount of zirconium used in the composition increases. This suggests that the optimal amount of zirconium to be used in the composition is 0.7 at.%, while the optimal ratio of La / (La+Ce) should not exceed 0.2.

[0162] Table 1 further shows that the maximum energy product ((BH)max) of the magnetic powders peaks at a La / (La+Ce) ratio of 0.2 when varying the amount of lanthanum used, while the (BH)maxof the magnetic powders peak at 0.7 at.% of zirconium when varying the amount of zirconium used. This suggests that the maximum all-around strength of the magnetic powder is achieved at the composition of (Ceo.sLao,2)i4.3Fe78.siZro.7B6.i.

[0163] Table 1 also illustrates that all magnetic powders exhibit a very fine nanoscalc grain size. Further, it can be seen that as the amount of zirconium used in the composition increases, the grain size of the magnetic powders significantly decreases. Additionally, as the amount of lanthanum used increases, the grain size of the magnetic powder slightly decreases, peaking at a La / (La+Ce) ratio of 0.2. Example 2: X-ray diffraction pattern analysis of magnetic powders

[0164] From Figure 1, it is shown that all magnetic powders have the (CeLa)2FeuB compound as the main phase. Further, an additional CeFez phase is present in CeuFeyg.gZriBs.i but was suppressed when La was added to the composition. The CeFez phase decreased in intensity when La / (Ce+La) increased from 0 to 0.1 and was completely suppressed when La / (Ce+La) > 0.2. The CeFez phase is known to be a paramagnetic material that decrease the magnetization of cerium-containing magnets. The CeFez phase also induces kinks in the hysteresis loops of cerium-containing magnets, resulting in the reduced remanence value (Br) and maximum energy product ((BH)max). Hence, the suppression of the CeFez phase contributes to stronger magnetization in (CeLa)- containing magnets.

[0165] Additionally, the peaks corresponding to the 2:14: 1 main phase shift to a lower 29 angle as La / (Ce+La) increases (Table 2), showing that the lanthanum was successfully substituted into the 2: 14: 1 phase lattice. This is because lanthanum has a larger atomic radius than cerium. As the amount of lanthanum used increases, the number of lanthanum atoms introduced into the 2: 14: 1 phase similarly increases, and hence the lattice parameter increases.

[0166] From Figure 1, it can be also seen that no additional phase or peak position shift was observed as Zr substitution increases, suggesting that zirconium substitution does not cause a significant change in phase presence and peak position.

[0167] Example 3: Magnetization of magnetic powders

[0168] As shown in Fig. 2 and Table 3, a standard Nd-Fc-B magnetic powder requires a magnetizing field strength of 4.5 T to be fully magnetized, due to its high intrinsic coercivity value (HCi) of about 16 kOe. Conversely, a standard CeLa-Fe-Zr-B magnetic powder only requires a magnetizing field strength of 2 T for it to become fully magnetized due to its lower intrinsic coercivity value (Hc0 of about 5 kOc.

[0169] Example 4: Powder quench stability

[0170] T

[0171] 6 samples of each composition of magnetic powder as shown in Table 4 were produced at the same processing conditions described in Example 1. Their magnetic properties were then measured with a VSM and summarized in Tabic 4. The results show that there is significantly less fluctuation in terms of remanence value (Br) in magnetic powders containing zirconium than magnetic powders without zirconium. This demonstrates that including a zirconium substitution in the composition of the magnetic powder improves its quench stability during the melt-spinning process, resulting in more stable and repeatable magnetic properties.

[0172] Example 5: Magnet compressibility

[0173] As mentioned in Example 1, the grain size of the magnetic powder decreases as the amount of zirconium substituted in the composition increases. Zirconium has a smaller atomic radius than cerium, and generally known to substitute rare-earth metals in the 2:14:1 phase lattice. It follows that a magnetic powder with a smaller grain size will be more compressible during the formation of a bonded magnet, and result in a bonded magnet with higher density. Fig. 3 shows that zirconium- containing bonded magnets exhibit significantly higher magnetic density and magnetic compressibility over CM bonded magnets that do not contain zirconium at any pressing pressure between 3 to 9 tons / cm2. Example 6: Magnetic properties of compression-moulded bonded magnets

[0174] The compression-moulded (CM) bonded magnets were prepared from their respective magnetic powders by first mixing the powders with 1.5% epoxy binder and 0.2% zinc stearate lubricant. About 2.8 g of the mixture was loaded into the cylindrical mould (<t> 10 mm) of KZK Powder Testing Center PTC-03DT, then pressed into green compacts with pressures of 650 to 900 MPa. The green compacts were finally cured inside oven at 180 °C for 30 min into CM magnets (<t>10*6.4mm, 6.0 g / cm3density). The second quadrant demagnetization curves of the CM magnets were measured by a Magnetic Instrumentation / KJS Associates HG-700 DC magnetic hysteresisgrapher.

[0175] Table 5 shows that that magnetic properties of CM bonded magnets follow a similar trend as those of the corresponding magnetic powders as shown in Table 1. The Br, Hcand (BH)masvalues of the CM bonded magnets arc lower than the corresponding values of the magnetic powders, as the the magnetic powders were diluted by the addition of a binder in the process of forming a CM magnet, while the Haof the CM bonded magnets are slightly lower as compared to the corresponding magnetic powder due to processing impacts. Table 5 further shows the best all-around magnetic performance is achieved with the composition of (Ceo.sLao^MjFeyg.sZro.rBe.i, having magnetic properties of Br=4.69 kG, Hc, =5.1 kOc, Hc=3.4 kOc and (BH)max=4.1 MGOc.

[0176] Example 7: Magnetic properties of injection-moulded bonded magnets

[0177] The injection-moulded (IM) bonded magnets were prepared from their respective magnetic powders by first crushing the magnetic powders into -80 mesh powders and mixing with 10 wt% PA12, 1 wt% coupling agent, 0.5 wt% anti-oxidant and 0.5 wt% lubricants using high speed mixer. The mixture was then made into compound pellets (size ~3mm) using a twin screw extruder at 230-250 °C. The compound pellets were finally made into IM magnets (<D10*6.4mm, 4.6 g / cm3density) by melting at 230- 250 °C and injecting into cylindrical mould using an injection moulding machine. The second quadrant demagnetization curves of IM magnets were measured by a Magnetic Instrumentation / KJS Associates HG-700 DC magnetic hysteresisgrapher.

[0178] Table 6: Magnetic properties of IM bonded magnets

[0179] Composition (at. %) BrHdHc(BH)maxDensity

[0180] (kG) (kOe) (kOe) (MGOe) (g / cc)

[0181] Table 6 shows that magnetic properties of the IM bonded magnets also follow a similar trend as their corresponding magnetic powders as shown in Table 1. The Br, Hcand (BH)maxvalues of the IM bonded magnets are lower than the values of their corresponding magnetic powders and also slightly lower than the values of CM magnets (Table 5). This is because in the formation of IM magnets, the magnetic powders were more diluted by the binder due to addition of a higher percentage of binder during the process, while the HCivalue is lowered due to processing impacts. Table 6 also shows the best all-around magnetic performance is achieved with the composition of (Cco.RLan.2)i4.3Fc78.9Zro.7B6.i, having magnetic properties of Br=3.33 kG, HCi=5.0 kOc, Hc=3.3 kOc and (BH)max =2.3 MGOe.

[0182] Additionally, the B-H lines of all compositions are maintained at a straight line up to a temperature of 120 °C (Figs. 4a-4f). This shows their suitability for use in motor applications for temperature up to 120°C.

[0183] As evidenced in the examples above, the inventors of the present invention have surprisingly found that the magnetic powders and bonded magnets of the present invention may comprise cerium while still maintaining good thermal stability and retaining high HCiat high temperatures. The inventors have also surprisingly found that magnetic powders comprising lanthanum show improvements in their magnetic strength and magnetic flux density. Further, the inventors have surprisingly found that the addition of zirconium to cerium- and lanthanum- containing magnetic powders improves the quench stability of the powder, allowing the powders to have more stable and repeatable magnetic properties. The addition of zirconium also results in a smaller grain size of the magnetic powder, hence when forming a bonded magnet with the magnetic powder, the compressibility of the bonded magnet is significantly improved, resulting in a bonded magnet with higher density. The inventors have also surprisingly found that a lower magnetizing field strength is required to fully magnetize cerium- and lanthanum- containing magnetic powders, which makes the magnetic powders and bonded magnets easy to produce in mass production. The cerium- and lanthanum- containing magnetic powders and bonded magnets have the further advantage of being significantly cheaper to produce, and have a high performance to cost ratio.

[0184] While Nd and Pr may be present in the magnetic powders and bonded magnets, their presence will increase the overall cost of the magnetic powders and bonded magnets. The present invention advantageously provides magnetic powders and bonded magnets that may comprise mainly or only of cerium and lanthanum as the RE component while maintaining good magnetic properties. Such magnetic powders and bonded magnets are desirable due to their lower cost of production. Comparative Examples

[0185] Comparative Example 1

[0186] Common cerium-containing magnets with formula Ce-Fe-B form a hard magnetic CezFewB phase which give the alloys their magnetic properties. A common drawback of cerium-containing magnets is the formation of the paramagnetic CeFe2 phase, which causes a reduction in the magnetic strength of the magnets.

[0187] Example 2 shows that the introduction of lanthanum into the composition of the magnetic powders leads to its introduction into the 2: 14: 1 phase lattice. Lanthanum has a higher atomic radius than cerium due to the effect of lanthanide contraction. This substitution of lanthanum is evidenced by' the decrease in the 29 angle in the XRD analysis, showing that the lattice parameter of the 2: 14: 1 phase is increased. This leads to suppression of the CeFe2 phase as shown in Fig. 1 , which gives the magnetic powders and bonded magnets improved magnetic properties.

[0188] Example 5 shows that the addition of zirconium into the composition of the magnetic powders also leads to its introduction into the 2: 14: 1 phase lattice. Zirconium is generally understood to be situated in the rare-earth sites of rare-earth magnets when substituted. Zirconium, having a lower atomic radius than cerium, through substitution of the rare-earth atoms in the lattice, lowers the lattice parameter of the 2:14: 1 phase lattice, thereby refining the microstructure of the magnetic powders, reducing the grain sizes of the magnetic powders, and hence improved magnetic compressibilities of the bonded magnets.

[0189] Therefore, the results of Examples 2 and 5 generally illustrate that both lanthanum and zirconium disrupt the lattice of the 2: 14: 1 phase of magnetic alloys, with lanthanum generally increasing the lattice parameter of the magnetic alloys to suppress the formation of the CePe2 phase, while zirconium generally decreases the lattice parameter by substituting the rare-earth atoms in the lattice. This suggests an inherent antagonism between the roles of lanthanum and zirconium.

[0190] However, as evidenced in the examples above, the inventors of the present invention have surprisingly found that by adding both lanthanum and zirconium to the composition of the magnetic powders, they combine synergistically to give the magnetic powders and bonded magnets as disclosed herein improvements in their magnetic properties by suppressing the CeFe2 phase while reducing the grain size of the magnetic powders. At the same time, these magnetic powders are thermally stable up to high temperatures, and experience greater quench stability and magnetizing ability. The bonded magnets made from these magnetic powders have the further advantage of being significantly cheaper to produce.

[0191] Comparative Example 2

[0192] Ferrite magnets generally have a low cost of production while maintaining good magnetic properties for everyday applications. They arc also generally resistant to being demagnetized up to high temperatures. However, they remain unsuitable for use for certain applications, such as ceiling fans and cooling fans, due to the difficulty of forming a ring-shaped ferrite magnet. Furthermore, it is difficult to achieve multiple pole magnetization in ferrite magnets, further reducing its use in everyday applications.

[0193] The inventors of the present invention have found that the composition of magnetic alloys as disclosed herein are suitable for formation of a ring-shaped magnet. It is difficult to make ferrite magnets in a ring shape for use in said applications as high-grade ferrite powder precursors are generally anisotropic, and require an external magnetic field to align the powders along the radial direction to achieve its full performance potential. This is difficult to achieve practically, resulting in ferrite magnets being unsuitable to mould into ring shapes, and unsuitable for said applications. However, the magnetic powders of the present invention are isotropic in nature and are not magnetized in any particular direction. The bonded magnets of the present invention are hence able to be moulded into a ring shape for use in said applications.

[0194] Further, ferrite has been found unsuitable for high number of magnetic poles magnetization on a ferrite ring magnet due to its magnetically anisotropic nature as described above which requires complex alignment tools. However, the inventors of the present invention have found that the composition of magnetic powders as disclosed herein arc suitable for multiple pole magnetization due to its magnetically isotropic nature. The magnetic powders and bonded magnets of the present invention are hence more suited to a greater number of applications as compared to ferrite magnets.

[0195] Industrial Applicability

[0196] The present invention generally relates to alloy compositions and their usefulness in magnetic powders and bonded magnets. The bonded magnets of the present invention can be used and applied in numerous applications, including motors, computer hardware, consumer electronics, and automobiles. It is beneficial for such bonded magnets to possess superior magnetic properties and exhibit high Brand HCivalues.

[0197] Advantageously, the disclosed bonded magnets may comprise cerium while maintaining good thermal stability and high IT at higher temperatures of up to 120 °C. The disclosed bonded magnets may also exhibit improved magnetic strength, magnetic flux density, quench stability, and magnet compressibility. The disclosed bonded magnets also require a lower magnetizing field to be fully magnetized.

[0198] Further advantageously, due to the above improved magnetic properties, the material cost of the disclosed bonded magnets may be lower, and the disclosed bonded magnets may be more cost- efficient. The disclosed bonded magnets may be produced by two different processes which shows their versatility for different applications.

[0199] It will be apparent that various other modifications and adaptations of the invention will be apparent to the person skilled in the art after reading the foregoing disclosure without departing from the spirit and scope of the invention and it is intended that all such modifications and adaptations come within the scope of the appended claims.

Claims

ClaimsWe claim:1 . An alloy composition of Formula (T):wherein:RE1represents (Cei.xLax);RE2represents (Ndi-uPru);0 < v < 0.1;0 < x < 0.5;0 < u < 1;10 < y < 20;0 < w < 5; and4 < z < 8, wherein u, v, w, x, y, and z are atom%.

2. The alloy composition of claim 1, wherein 0 < v < 0. 1.

3. The alloy composition of claim 1 or 2, wherein v = 0.

4. The alloy composition of any one of claims 1-3, wherein 0 < x < 0.3.

5. The alloy composition of any one of claims 1-4, wherein 12 < y < 16.

6. The alloy composition of any one of claims 1-5, wherein 0 < w < 2.

7. The alloy composition of any one of claims 1-6, wherein 5.5 < z < 6.5.

8. The alloy composition of any one of claims 1-7, wherein the alloy composition is selected from the group consisting of:• (Ceo.gLao.iluFevs.sZriBg.i9. The alloy composition of any one of claims 1 to 8, wherein the alloy composition comprises crystal grain sizes in the range of about 20 nm to about 30 nm.

10. A magnetic powder comprising the alloy composition of any one of claims 1-9.

11. The magnetic powder of claim 10, wherein the powder exhibits a remanence (Br) value of greater than about 5 kG.

12. The magnetic powder of claim 10 or 11, wherein the powder exhibits an intrinsic coercivity (HCi) value of greater than about 4.0 kOc.

13. The magnetic powder of any one of claims 10-12, wherein the powder exhibits a maximum energy product ((BH)max) value of greater than about 5.5 MGOc.

14. A bonded magnet comprising the magnetic powder of any one of claims 10-13.

15. The bonded magnet of claim 14, wherein the bonded magnet is a compression-moulded magnet or an injection-moulded magnet.

16. The bonded magnet of claim 14 or 15, wherein the bonded magnet:(i) is a compression-moulded magnet which has a density of about 5.70 - 6.30 g / cc; or(ii) is an injection-moulded magnet which has a density of about 4.30 - 4.90 g / cc.

17. The bonded magnet of any one of claims 14-16, wherein the bonded magnet:(i) is a compression-moulded magnet which exhibits a remanence (Br) value of greater than about4 kG; or(ii) is an injection-moulded magnet which exhibits a remanence (Br) value of greater than about 2.8 kG.

18. The bonded magnet of any one of claims 14-17, wherein the bonded magnet:(i) is a compression-moulded magnet which exhibits an intrinsic coercivity (HCi) value of greater than about 3.5 kOc; or(ii) is an injection-moulded magnet which exhibits an intrinsic coercivity (Hci) value of greater than about 3.5 kOe.

19. The bonded magnet of any one of claims 14-18, wherein the bonded magnet:(i) is a compression-moulded magnet which exhibits a maximum energy product ((BH)max) value of greater than about 3.5 MGOe; or(ii) is an injection-moulded magnet which exhibits a maximum energy product ((BH)ma) value of greater than about 1.8 MGOe.

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