Fully dense anisotropic nanocomposite Sm(Co0.58Fe0.31Zr0.05Cu0.04B0.02)z (z=7.5–12) magnets have been synthesized via rapid hot pressing and hot deformation processes. The highest (BH)max∼10.6MGOe was observed for a magnet with z=10. X-ray diffraction and M-H measurements indicated that the easy magnetization direction of magnets prefers to be in the hot pressing direction. Transmission electron microscopy investigation confirmed that plastic deformation is an important route for forming magnetic anisotropy in the Sm–Co-type nanocomposite magnets. Some stripe and/or platelike patterns have been observed inside the nanograins (50–200nm), which may present as twins, and stacking faults. The (0001) twins have been observed in the 2:17R phase.

Structure and magnetic properties of both melt-spun and hot deformed bulk Sm–Co type nanocomposite magnets have been investigated with various metal additions, including Zr, Cu, and Nb. The Zr and Nb additions play important roles in constraining grain growth, resulting in an increase of coercivity Hc. The Cu addition significantly improves the squareness of BH loops as well as the energy product (BH)max. A typical hot deformed bulk anisotropic nanocomposite SmCo type magnet with Mr(hard)∕Mr(easy)∼0.4, Hc∼9kOe and (BH)max of 13.2MGOe was obtained.