Patent ID: 7794557

Claim:
A method of tape casting a material, comprising: drying a first mixture comprising one or more chemical precursors and a liquid medium at a temperature effective to form agglomerates; grinding the agglomerates to form a precomposite powder comprising the one or more chemical precursors; combining the precomposite powder with a binder to form a second mixture; casting the second mixture to form a green tape; and heating the green tape for a time and at a temperature sufficient to convert the chemical precursors to their final chemical phase, and to anneal and form the material wherein the material comprises a composite selected from the group consisting of Fe—Ni/Silica, Co/Silica, Fe/Silica, Ni-Ferrite, Fe—Co/Silica, Fe—Co and (FeCo) 1-x (Al 2 O 3 ) x where x is greater than zero and less than or equal to about 0.50.