AU2002309001B2 - Means of making wide pole face cobolt-rare earth magnets - Google Patents

Description

1- This is a complete specification following provisional applications PR 70'50 of the 16/S/Cl end PR 8803 of the 12/11/Cl and PS 3219 of the 26/6/02 which essentially use a pulse system of magnet isation on powoer compacts of powders of sub-mnicron parricie sizes (a mnicro-n boi--io a one-maillionth of a meter or l0m).Fabrication of ~c~ni~~-P~re Earth magnets is along linesoPetPantNm ber 737,1338 of the 91/31/01 (Application 21,22r6/01 of the,; 15//0) snd b'asically Oxide powLAder ingre-dientS ar crushed. by (preferably) ball 1MIiI J'IIc t-.sub-micron particle size s then pesdwithsbmaLcron carz-. u >Tder (b--all milled seoaratelv) a nd sintered at 800C aori o)ver ru irrnii J1 sil arilnr brick cavity aid -7P ame Viatec on top ofi a 1mune1 sation c-ias in Petty patent 7_37, 188 wbr cavity rq l i -11i r m -r r i-A 4a r, r(qDixide an rJ 1'ut-, rf, mtal or: renerths amd relan~ matrials at ab'_our. ;iifl 0 and Carmrn ai-r r r 4-v. rz T- I- 1 ;flnln Ihz A rr lz rcn j~eS 1; v 11 L~ Alv thlis p a te t a eS s t ha -,-micreOns) '1te ai ,n typ7-eS cf Ccbol1t cre La~ magnet are Lac wihenn amadgnism (Br a:i .91 es, CeCos of Br =77Tesla. PrCos of Dr =12 Tesla, NUICo5 Of Br =1.22 Tesla, SinCe' of Br, 1.00 Tesla and Sm(CCoo.7rFeoloCulo14c,. cf P_ Tesla. Basically these Rare--Earths inter-m-Tetallics are fabricated fro-m ball mi-illed sub)-micron oxide oo~wders of about less than 0.2 micronc ard reducedl to base metal comnounds or inter-metallics whereas hai Thzfrrites are man-ufactured in. the sae arle ste-0 manner but without the addition of Carbon pow-der to reduce oxides 2 so the single step fabrication just involves reaction of component oxides and allignment of growing crystal in imposed magnetic field at slightly lower than the Curie Temperature and cooling in the imposed magnetic field to form Ferrite magnet. In this single step process where the Curie Temperature for Ferrites like Barium Ferrite (BaFel2019) and Strontium Ferrite (SrFel2i19) is about 4000C and this means for such the a low operating temperature in this single step fabrication method very fine powders have to be used at less than 0.05 microns for the oxides to react and resultant crystals to allign in imposed magnetic fields. To achieve these very fine powders speciallized ball milling procedures are employed. So for these very small sized magnetically formed crystals in particularly Ferrites and even Cobolt-Rare Earth materials magnetisation and domain formation becomes a problem so higher magnetic fields have to be applied and this is achieved by pulsing the current through the magnetising coil by repeated charging and rapidly discharging a capacitor and this intensifies the current and hence and the applied magnetic field by over 10x for the brief interval which the capacitor is discharged. This very high applied magnetic field pulsing has the affect to order the crystal during this single step fabrication procedure and because of the very small resultant magnetic crystal and the difficulty of moving magnetic domain walls of such very small proportions results in a very magnetically'pure' crystal that has has been formed in the very intense applied magnetic field pulses that significantly order the crystal's internal solid perfection during this single stage fabrication procedure.

So the resultant magnetic crystal has been formed at high applied magnetic field strengths by domain wall or boundary motion or formation that has very much resisted motion or growth thus making the 3 magnet material very resistant to de-magnetisation or magnetic relaxation so 'soft' magnetic materials like Fe304 become affectively a 'hard' magnetic material or one that resists de-magnetisation or magnetic relaxation. For a material like Fe304 that oxidizes to Fe203 at around the Curie temperature in hot air a reducing oas blanknt of Carbonly Dioxide and Carbon Monnoiie is neccessary to Irvejnt tgis sa heatin- flame hasq to be slihtlI reducing toa prvent thi- i idi ati Aon procss and insulating cavity where powder ri bppas I-r drriAt- cstal r fin n-t- and m-ge allignment and groithl In th i i El se f Pa1readx formo2d V-0 4 th j: L .Ary fine 2 aCr r L l ilin) ist at ligne i L LI L -i f to .c tesla cont-nuous apv11ed eld) anf 'hen dried and copactedan"- th1en heated at slightly lo-wer ta h ui temperatu r in the pulsing magne tic field in this slightly reducing a t oSpher. pulse Lagnesatio is echieved with a 200 r1,I Dvol t up ply a th a plsing treuency at 1'0x nCC4PWaeS per c3n a3 L n he heatcd p er compa e4:g puasi Sag zo 10

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,h=ach pt:'sa c'- -ac -us faot olms -frozF thrn capacitor I eliv4ers abo3ut 503 cEp6 f 1) 3 secondjs lx milll-secUnd and capdcituL re-chaiges cetween pulses during this 10-2 second cycle interva±. The switching system is described in Figure 3 of this invention system.

Each magnetic coil configuration or coil must have a resistance of about 0.012 ohms which means that coils have 250x or more windings for not more than 25x meters to two parallel strands of 3mm. by 6mm. copper enamel strip winding material and during each pulse this is about 1.667 x 106 amns.turns/meter for a system as in 737.188 for makino flat wide pole magnets with a magnet field perpendicular to wide pole face. So the affective magnetic field in 4 such a- case is 2.1 tesla. This system can be scaled up in terms of applied magnetic field or pulsing magnetising field by increasing the voltage and power of the D.C. power supply for this existant set of coils. So a 12 volt power supply supplying 800 watts gives a applied field of about 4.2 tesla and a 24 volt power supply supplying 3,200 watts gives a applied field of about 8.4 tesla. The main advantage of this is that with magnetically internally ordered crystal during single step magnet formation this acquired magnetic ordering gives enhanced crystal orders in the high strength pulsing magnetic field that are particularly favorable to domain formation and as a result the resultant remnant magnetisation a higher than reported literature values are achievable with achievable Barium Ferrites remnant magnetisations of over Ix tesla and Samarium- Cobolt Rare earth material having achievable remnant magnetic field strengths of over 5x tesla. The following 3x Figures describe this invention. Figure la shows the magnetisation system similar to Petty patent 737,188 with 1 the two parallel strip windings around iron base 2 with field lines 3 eminating through powder compact 6 which is being reduced by carbon powder present and shrinks 7 in a controlled way so that no significant distortion or spalling occurs with block 6 being heated by torch 8 with mixed gases for combustion 9 being burnt in flame 10 with hot gas spread 11 heating compact 6 and reducing gas mix or Carbon Dioxide gas cover 13 and Carbon Dioxide released 12 from powder compact and these releases being heavier than air and settling in thermal insulation cavity where powder compact 6 rest on base insulation pad 4 over Iron winding former 2 with side insulation ring 5 helping contain released Carbon Dioxide which is heavier than Air with Carbon Dioxide slowly diffusing through porous thermal insulation 5 and base 4. A thermo- 5 couple checks operating temperature so that temperature does not go over Curie Temperature.Figure lb shows the various magnetic configations to produce rings and rectanguloid blocks with varied magnetic field orientations. Figure ibl shows the basic block formation with magnetic field perpendicular to wide face with 1 the dual magnetic strip wound around iron former 2 with 3 the eminating magnetic field that magnetizes block 6 that is the forming magnet inside thermal insulating base 4 and thermally insulating sides 5 heated by flame 11. The porous,thermally insulating cover 4 and 5 allow gases to diffuse through and escape while still retaining a significant amount of heavier than air, Carbon Dioxide to create the reducing atmosphere around the forming magnet block. Figure lb2 shows a basic magnetic ring formation 6 with dual coil strips 1 being wound in a wide iron spool 2 with magnetic field 3 eminating radially through forming magnetic ring 6 with porous thermally insulating side cover 5 on porous insulating base cover 4 helping retain the reducing gas cover over the magnet ring 6 which is heated by flame 11. Figure ib3 shows a basic rectanguloid block magnet being formed with a parallel to surface magnetic field so that magnetic field 3 from wide iron spool 2 with dual strip windings 1 in spool 2 eminates radially across surface of spool 2 and block 6 retains parallel to surface (or wide face) magnetism. The thermally insulating porous side cover 5 and thermally insulating porous base 4 helps retain reducing gas atmosphere around forming magnetic block which is heated by flame 11. Figure lb4 shows a basic narrow ring magnet being formed with a concentric circular ring magnetic field.

The Iron ring 2 has a dual strips wound 1 around it to form a toroid with forming magnetic ring 6 having circular field 3a and 3b eminating through it (3a field line out of page and 3b field line 6 into page). A thermally insulating side cover 4 insulates windings 1 on Iron ring 2 from flame, heat source 11 with reducing gases filling cavity during magnetic ring formation of pulse magnetization. Figure lb5 is the same as Figure lb4 only for a wide ring magnet with a circular field with 2 the wide iron ring former for dual strip windings 1 that form toroid with circular resultant magnetic field 3a and 3b eminating through wide, forming magnetic ring 6 with 3a field line out of page and 3b field line into page.

The thermally insulating base 4 insulates winding 1 with porous, thermally insulating side cover 5 helps retain reducing atmosphere from flame or heat source 11 and Carbon Dioxide from forming magnet ring that is being reduced as powder compact. Also crucial to the invention is the formation or crushing of very fine powders to less than .lx microns (one micron is 10-6 meters) and this usually involyes 'wet' ball milling (in water as a sludge) so with 500x balls of 3/8 inch diameter in a cylindrical cavity with about a 155mm. internal diameter turning at about 180 revolutions per minite with the cylindrical drum being about 120mn. long with rotation speed being very accurately controled by a induction motor speed controller to give maximum tumble speed of the balls in the ball mill which flatten elastically and significantly increase the contact volume at the required sub-micron diameter so a operation to mill a quantity of about 100 cubic centimeters of powder (as solid volume) would take over 1,000 hours of milling or rotation of ball mill with wet powder sludge and balls and this is considerably long and gives considerable wear of steel balls (precision steel balls used in bearings) of about lx micron in diameter for every 10 hours of milling with basic soft powders like Ferric Oxide and Barium Carbonate. So by maximizing rotation speed without flinging out balls 7 too hard against side, the balls tumble and by maximizing this tumble speed the balls on contact flatten elastically on impact thus significantly increasing the sub-micron contact volume thus taking a 1,000 hour operation and over to less than 200 hours to achieve average diameters of less than 0.05 microns. Figure 2al shows a impact collision between two balls 15a and 15b with a small impact force 16a at lower tumble speeds so that a smaller submicron contact volume of powder 17a is crushed but in Figure 2a2 the impacting balls 15c and 15d impact at higher tumble speeds and impact force 16b is higher thus flattening more surface at contact zone thus increasing the sub-micron powder contact volume thus giving much shorter cruching times and longer lifes of the steel balls used in the crushing process. Figure 2b is a basic layout of the Ball Mill used in the crushing process with the end plate 18 having a bearing so drum with balls 23 can rotate 28 driven by by 'Vee' belt 21 over pulley 22 on end of shaft on end plate 23 of cylindrical drum of ball mill fastened by screws 24 with shaft of drum through end plate of housing 18 in bearing with ball mill drum being driven by 240 volt Induction motor 19 which drives through a gear box to give the about 180x Revolutions per second through pulley 20 on end of gear box of Induction motor 19 with Gear-box, Induction motor bolted to end plate 18 of mill housing at bolt locations 27. The end plate 18 of ball mill housing has a base for stand of ball mill housing. A screw with rubber ring 26 near the outer part of cylindrical part of ball mill seals the ball mill and allows insertion of extra water and surfactant into the ball mill when hole in end plate of cylindrical ball mill is at top rotation position. The extra water and surfactant inserted at specific times during the milling process when powder slurry is 8 starting to thicken due to extra surface area generated by the crushing of the powder and this maximizes the tumbling speed by thinning the slurry and this is essential for ball interface flattening on contact which Significantly decreases the crushing time.

Figure 3a is a top view of the pulsing system or time fraction switch which discharges the capacitor into magnetizing coil to give higher than normal or constant currents through magnetizing coil.

So with the coil being about 250x turns of two parallel strips of 3mm. by 6mm. Copper enamel which is at 6 volts and 200 watts continuous supply feeding into capacitor (which is just a off the shelf 150,000 Micro-farad capacitor rated at up to 10 volts) giving about 1.667 x 106 amp.turns/meter (or about 20,950 Oersted) or a equivalent field strength of 2.1 tesla for 1x milli-second with pulse being repeated at up to 100x times per second. So Figure 3 is the means of switching capacitor within Ix milli-second at up to 100x times per second with this top view being principally a small D.C.

electric motor at around 12 volts 29 which turns at about 3,000 Rotations per minute so that motor shaft 30 turns 31 with (preferably) nylon wheel 32 fixed on shaft 30 by screw nuts 41a and 41b with two humps 33 on wheel's 32 outer edge so as wheel 32 rotates the hump drags accross plate surface thus elevating plate for a fraction of rotation time with springs returning plate to non-contact position so that electrical contact is made about twice every rotation of wheel 32 as opposed humps push spring loaded plate up to make electrical contact with other contact surface. So top plate 34 is stationary fixed by fasteners 35 with over-hanging edges of moving base plate 36 which slides up and down on slide rods 38 in guide hole 37. The electrical contact between negative connection 39 on top plate and positive connection 40 on moving base plate is 9 thus made as hump pushes base plate 36 up to contact top plate 34 and when hump 33 has draged past springs return base plate to noncontact position. Figure 3b is a side view of this repetition switching for capacitor with 29 the motor mounted on base by brackets 42 and bolts 43 with motor shaft 30 turning nylon wheel 32 which is fixed on end of shaft by screw nuts 41a and 41b and as shaft 30 rotates 31 the humps 33 drag accross under surface of moving base plate 36 which contacts fixed top plate 34 fixed to bracket 44 on side mounting assembly for motor with side bracket 44 being fastened by bolts 45 with top plate 34 electrically isolated from mounting bracket 44 by plastic thin sheet 46 with fasteners for plate 34 also being isolated electrically from 44 by plastic washers. The inside slide rods 47 are electrically isolated from mounting bracket 44 with plastic washers between screw nuts of plate of mounting bracket 44 and top plate 34 between plastic film 46 with slide rods 47 through moving base plate 36 being Epoxy resin coated to electrically isolate slide rods 47 from connector plate 36. Outer slide rods 38 are again electrically isolated from mounting bracket plate 44 by plastic film and plastic washers between locking screw nuts with electrical isolation of slide rod through moving base plate 36 through holes 37 a plastic liner bush 49 is used with plastic screw locking nut 48 and plastic liner base also electrically isolates springs 55 so as nylon wheel hump 33 presses base plate up against top plate electrical contact is made within ix milli-second the springs 55 through slide rods 38 return base plate assembly 36 to electrical non-contact position or spaced position as humps 33 passes about 100x times per second. Electrical input current (-ve terminal) contact 39 is made to top plate 34 and electrical output current (+ve terminal) contact 40 is made to mov- 10 ing base plate 36. Because sparking can occur on electrical contact between base plate assembly 36 and top plate assembly 34 it is neccessary to have materials that resist sticking on any sparking at contact so Tungsten Carbide strip 51 is Silver soldered or Gold soldered (PR 9530 of the 18/12/01) to bottom of top plate 34 to prevent any 'sticking' if any electrical arcing occurs. Similarly for the moving base plate assembly 36 this is in two sections with a bottom brass half 52 bolts to upper half 53 by bolts 54 with upper half that makes electrical contact with Tungsten Carbide strip 51 of top plate assembly 34 being of Sintered Tungsten powder (sintered in Hydrogen at about 8000C) with Silver Nitrate and Ruthenium Nitrosyl Nitrate as solutions added to Tungsten powder as solutions with powder then mixed and then dried and then sintered in inert gas initially to heat Silver and Ruthenium salts back to metal with final sintering achieved in Hydrogen to give Tungsten block 53 which can be drilled and tapped to fasten this Tungsten block 53 to brass bottom 52 of base plate assembly 36. This Tungsten surface of block 53 resists sticking if electrical arcing occurs on contact and so plates 34 and 36 keep opening and contacting as humps 33 close gap and close circuit up to 100x Limes per second within abouL Ix milli-second per each conLact. Figure 3d is of the electrical circuit involved in magnetizing the magnet material with the transformer 57 stepping down the mains power 56 with the about 6 volt output of transformer 58 going through a diode bridge 59 to rectify the current to D.C. with a capacitor 60 to smooth current with positive output 61 going to discharge capacitor 63 and negative output 62 also to 63 and this capacitor 63 then discharges through switch assembly 64 of Figure 3b through leads 39 and 40 into magnetizing coil 1 that magnetizes magnet material.

Claims (3)

1. A single step magnet formatio orocess involving the ball mill- ing of Oxide powders to less than about 0.4x micron diameter so thait. Oxido powders are mixed and then pressed into a compact being o 5 a hollow ring disc or rectanguloid shape and for the case of 0\ o Cobolt-Rare Earth magnets, the powders are mixed with sufficient g carbon powder (also less than 0.4x microns about in diameter) and o heated in a enclosure to slightly less than the Curie temperature to retdure to hAsi met-allic or inter-metallic compositions so that IO cumpacL L reducing gaseous atmosphere such that resultant heavy gaseousi Carbon Dioxi.de from reductinn process settles in cavity where compact is being heated so oxidation is very significantly reduced so that this reducing atmosphere flows around compact and heavier Carbon Dioxide settles in cavity where, compact is heated as LCducingr, shrlirki n compact is piulse magnetised in pulsing high strength magneti fi.eld so that magnet individual crystals form during reduction and sintering and slight shrinkage in all.igned magnetic crystal Formation occurs, so that similarly for Oxide Perrite magnet manufacture where Ferrite component powders or single ferrite powders are heated at below Curie temperature so powder is fine enough for sintering and crystal formation and reaction to take place with formed crystal alligning in the magnetic field of the pulsing magnetic coil of high pulsed magnetic field strengths in a reducing atmosphere and resultant protective heavier than air atmosphere forms around compact where it is heated with the atmosphere preferably Carbon Dioxide so with this pulse system of magnetisation of sintered powder compacts are made from sub-micron powders being preferably ball milled to less than .4x microns and down to below .05x micron diameter so that the R, 9 d 98f.S9Z£ZO N 6:90 SL/9 d 98t'b99g10 NOq1OINO3 3DHoq9 6:90 0-L0-800g OZ-ZLO-809 (P-nfl-A) aea Lt:90 OauJ! :e!lJsnv dl Aq po!asoaH £1696 L-SOHV :ON CI SilOO 00 0 12 difficulty of magnetisation of these small crystals in terms of domain boundary growth renders 'soft' magnet materials like Fe304 becomes a 'hard' magnet because of the dificulty of domain boundary motion and also high strength magnetic field pulsing allows higher o 5 than normal final magnetic field strengths to be attained. 0 o 2. The single step magnet formation process as claimed in claim 1 where sub-micron powders from ball milling process where Oxide Spowders are ball milled wet with water and carbon powder for reduction is ball milled separately in hydrocarbon liquid such as Kerosine with hundreds of ball bearings in tumbler so that when oxide powders for Cobolt-Rare .arth magnet material are mixed with Carbon powder and bl tcnd and pressed into compact for reduction, reaction and sintering the compact is heated to slightly less than r.nirin tempe rature by gas fl.ame with rednoing gaseous atmosphere w i.Lh cormpdcl. hniel.ted irn c(:vil.y so he-v i r thrin i r resultant Carbon Dioxide from combustion fills cavity and prevent or very si.gni.ticantly reduces any oxidation of magnet material so that pulsing magnetic field expands magnetic domains and helps allign growing magnetic crystals during formation and during sintering, o reduction and reaction of magnetic material components.

3. The single stop magnet formation process as claimed in claim 1 where sub-micron powders from the ball milling process where Oxide powders and components are ball milled wet with water and mixed, dried powder is compacted into compact which is heated by a A- combustion flame to slightly less than the Curie temperature in a cavity so that reducing flame components which contains heavier than air, Carbon Dioxide can significantly reduce or prevent oxidation of magnetic material during heating that causes reaction, sintering and magnetic crystal formation to proceed in the pulsing SL/ d 98tS9zEzo NOOIN03 31903S 6S:90 OZ-zO-900Z OZ-ZLO-800OO aslea L7:90 awlL :e!lejJsnv dl Aq pAi!aoal £et6861 -SOHV :ON al SVOO 00 o

13- applied magnetic field which helps allign magnetic crystals and expands magnetic domain boundaries so that with 'soft' magnetic materials such as k'0304 become 'hard' magnetic material due to very •.small sub-micron crystal formal:ions as magnetic domain boundaries o 5 become very difficult to move during magnetisation or even de- 0O o magnetisation. (C 4. The single step magnet formation process as claimed in claim 1 S and describing the ball milling system of Figure 2 where steel ball tumhle speed. are maximized by using a speed controller on the induction motor that rotates the ball mill tumbler through a gear box where the speed controller is simply a diac fi.ring a triac so that maximized ball tumble speeds mean that balls collide at maxi- mum speed thus elastically defoming the balls and thus increasing contact vnolume of two colliding halls as balls elastic-aly flat tren nrid sn milling to less than .05x microns is attainable within a few hundred hours of continuous miling due to i creased volume of fine milled fraction at about 0,05 mi.crons and also as milling pro- gresses a i.nlet hole with screw and rubber ring seal near the periphery of rotation allows extra water or fluid to be i.nLcoduced into ball mill daring various times during milling progress so that as extra surface is generated in crushed powder extra fluid does not allow the slurry in the ball mill to thicken too much with exLra surfactant also added wi.th extra fluid during milling process to reduce thickening of slurry and keep slurry from becoming too thick and too dense such that it reduces ball colision speeds and reduces milling effectiveness to finer powders. S. The single step magnet formation process as claimed in claim 1 and describing the magnetic pulsing system of Figure 3 where a rot- ating plastic disc with two opposed humps rotates to push up a SL/8 d 9811S9ZEZO NOI301N0O3 93033 6S:90 OZ-ZO-8OOZ OZ-LO-900Z alec 11:90 (WU:H) awLU :e!lejisnv dl Aq paA!aaHl E3£686L-SOIV :ON (31 S9OO 00 0 OC 0 14 3 sliding bottom plate to make electrical contact with a stationary top plate within a milli-second so that discharge from capacitor can occur into a magnetic coil around a Iron former on which the powder compact is heaLud, sintered and reacted and magnetised in 0 o 5 the pulsing magnetic field from this wound coil activated by the o pulsed discharging capacitor with power supplied by a low voltage, C' high current D.C. power supply from rectified mains supply with C cectified supply having capacilor smoothed supply with milli-second switching system of this rotating plastic wheel with two opposed IO humps and contact plates with moving plate is of sintered tungsten powder to prevent sticking due to arcing on contact and spring separation of contacts wit.h stationary top plate having Tungsten Carbide strips hrazl.d onto top plate for contact and to prevent. arcinl nn contact- and spring return to non-contact position during repi.tion switching with a small, about. 12 volt Dn.C. motor rotating plastic wheel to make the about 1x milli-second lectrical contact to give the capacitor discharge into magnetising coil so capacitor re-charges between contacts that are forced to contact by the opposed humps on the rotating plastic wheel. 6. The single step magnet formation process as claimed in claim 1 where Cobolt-Rare Earth magnets are made from Oxide powders that have been ball milled to less that 0.4x microns in a water slurry in ball mill and mixed with sufficient Carbon powder that has been ball milled to less than 0.4x microns in a slurry with hydrocarbon liquid and powder compact is heated in reducing flame in cavity so that reactants react, and are reduced and sinter thus forming magnetic crystal in presence of pulsing high strength magnetic field so forming magnetic crystal that are allined in magnetic field and magnetic domain boundaries expand thropugh alliqned SL/6 d 98t'LS9ZE/O N03L01N03 «39033 t 6S:90 Oz-ZO-8OOZ OZ-LO-800Z (P-II-A) aie 1:90 aUJLL :e!lejsn dl Aq pa!aOal £17696L-SOIV :ON C1 SYJOO 00 o 15 crystal arrays in presence of pulsing magnetic field giving higher than normal resultant magnet field strengths due to the high a] applied puluing field strengths and the crystal growth with hard to expand magnetic domain boundaries. 7. The single step magnet formation process as claimed in claim 1 o where Barium Ferrite magnets are made from Oxide powders that have C] been ball milled to less than 0.4x microns in a water slurry in a o ball mill h.o even down to less han .05x m[crons so that dried powder is compacted and heated in cavity by reducing flame at less than Curie temperature in presence of pul.sing magnetic field so that compact of components react and sinter in pulsi.ng applied magnetic field thu. forming magnetic crystal that is magnetically alligned and magnetic domaiin walls expand through alligned crystal array in the high strength pulsing magrnetic field thus making domain motion very difficult during magnetisation so that higher than normal magnet field strengths are attained with these sub- micron powders in these high strength pulsing magnetic fields making 'soft' magnet materials such as Fe304 into 'hard' magnets resisting magnet domain motion in such small sized crystals. 8. A Single step magnet formation process as claimed in claims 1 to 7 as herein described with reference to accompanying drawings. GEORGE ANTHONY CONTO.LEON 28TI1. DECEMBER,2007. APPLICANT DATE SL/Ol d 98tsL9ZEZO N0301N03 3981039 6S:90 OZ-ZO-800Z