IRON-BASED MAGNET ALLOY POWDER CONTAINING RARE EARTH ELEMENT, METHOD OF MANUFACTURING THE SAME, RE

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PROBLEM TO BE SOLVED : To provide a rare earth/iron-based magnet powder for a bonded magnet, which enables the bonded magnet to have excellent moldability and mechanical strength when used as a composition for the bonded magnet, and to provide a method of manufacturing the same. SOLUTION : There is provided the iron-based magnet alloy powder containing a rare earth element, which includes : a composite metal phosphate film (A) containing an iron phosphate and a rare earth metal phosphate, and formed in advance on a surface of a magnet powder made of an iron-based magnet alloy containing the rare earth element, the film (A) being heat-treated; and a silicate film (B) formed for covering thereafter. Here, when the surface of the iron-based magnet alloy powder is analyzed by using an X-ray photoelectron spectrometer, Fe in a substantially metallic state is not detected in the alloy powder. There is provided the method of manufacturing the iron-based magnet alloy powder containing the rare earth element, which includes a process for adding and stirring a phosphoric acid during or after pulverizing a rough iron-based magnet alloy powder containing the rare earth element in an organic solvent, to form the composite metal phosphate film (A) on the surface of the magnet alloy powder, and separating and removing a solution from this magnet alloy powder slurry, and performing a heat treatment under reduced pressure and at a temperature of 100°C or higher, and the process of adding polyalkoxypolysiloxane to the magnet alloy powder at a ratio of 0.01 to 5 mass%, mixing and stirring, and forming the silicate film (B) on the surface of the film (A). COPYRIGHT : (C)2011, JPO&INPIT