Patent ID: 7160398

Claim:
A method of making a rapidly solidified alloy for a nanocomposite magnet, the method comprising the steps of: preparing a melt of an alloy having a composition represented by the general formula: (Fe 1-m T m ) 100-x-y-z Q x R y M z , where T is at least one element selected from the group consisting of Co and Ni; Q is at least one element selected from the group consisting of B and C and always includes B; R is at least one rare-earth element; and M is at least one metal element selected from the group consisting of Al, Si, Ti, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb, the mole fractions x, y, z and m satisfying the inequalities of: 10 at %≦x≦35 at %; 2 at %≦y≦10 at %; 0 at %≦z≦10 at %; and 0≦m≦0.5, respectively, and forming the rapidly solidified alloy by bringing the melt into contact with the surface of a rotating chill roller; wherein the step of forming the rapidly solidified alloy includes the steps of: arranging a guide member such that a guide surface thereof defines a tilt angle of about 5 degrees to about 70 degrees with respect to a horizontal plane, the guide member having a plurality of tubular holes with at least one of the plurality of tubular holes having a length of about 0.5 mm to about 50 mm and an opening area of about 0.02 cm 2 to about 0.5 cm 2 ; teeming the melt onto the guide surface of the guide member, and then feeding the melt, running down on the guide surface, through the plurality of tubular holes of the guide member directly adjacent to the guide surface and onto a contact area on the surface of the chill roller; and splitting the melt into a number of melt flows by way of the plurality of tubular holes and then bringing the melt flows into contact with the chill roller.