CN100380537C - Soft-magnetic composite material and process for making magnetic conduction component by using same - Google Patents

Soft-magnetic composite material and process for making magnetic conduction component by using same Download PDF

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CN100380537C
CN100380537C CNB2005100316147A CN200510031614A CN100380537C CN 100380537 C CN100380537 C CN 100380537C CN B2005100316147 A CNB2005100316147 A CN B2005100316147A CN 200510031614 A CN200510031614 A CN 200510031614A CN 100380537 C CN100380537 C CN 100380537C
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CN1700368A (en
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罗计添
谢德辉
李志民
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Abstract

The present invention relates to a soft-magnetic composite material which is characterized in that the soft-magnetic composite material comprises 92 to 99 wt% of iron containing raw material, 0.5 to 5 wt% of insulating compound and 0.5 to 3 wt% of lubricator, wherein the iron containing raw material is a dusty material which comprises reduced iron powder, atomized iron powder, hydroxy group iron powder and iron alloy powder, the iron content of the iron containing raw material is 80 to 99.8%, and the particle distribution is 20 to 500 meshes. The insulating compound adopts nanometer calcium carbonate powder or ceramic powder or magnetic oxide powder, and the lubricator is micro mist wax. A production process for manufacturing a magnetic conduction component by the soft-magnetic composite material comprises the following steps of mixing, formation, solidification, rust prevention or finishing treatment. Since the magnetic conduction component made of the material of the present invention has the advantages of wide material source, high iron content, less eddy current loss, low magnetic saturation induction density and high magnetic conductivity, specific resistance, magnetic property and mechanical property. A component processing technology has the advantages of low cost and high forming accuracy.

Description

A kind of soft-magnetic composite material reaches the method for being made conducting magnetic component by it
Technical field:
The present invention relates to a kind of soft-magnetic composite material, be specifically related to constitute in a kind of electrical equipment and electrical the soft-magnetic composite material of conducting magnetic component and make the method for conducting magnetic component by it.
Background technology:
Along with the development of society, has motor, the electrical equipment of conducting magnetic component, extensive use in daily life.At present, the conducting magnetic component material in these electrical equipment mostly is silicon steel sheet, is used for medium and low frequency transformer and electric machine iron core in a large number, especially Industrial Frequency Transformer.The characteristics of silicon steel are to have saturation induction density (more than the 2.0T) the highest in the soft magnetic material commonly used, can be at very high working point work (as work magnetic strength value 1.5T) when therefore using as transformer core.But silicon steel iron loss in soft magnetic material commonly used also is maximum, generates heat too greatly because of loss in order to prevent iron core, and its frequency of utilization is not high, generally can only be operated in below the 20KHz.Silicon steel generally adopts flaky texture, and its production craft step is:
1, earlier with silicon steel punched chip;
2, silicon steel sheet is assembled into required magnetic dentation;
3, silicon steel sheet is carried out the insulating barrier nursing, on the magnetic tooth, conducting magnetic component can produce magnetic field when copper cash is switched on copper cash.
But said method has apparent in view weakness, i.e. the direct cost height of Sheng Chaning, and reason is:
1., because the out-of-shape of various members, the utilization rate of material is lower, the waste material of being produced is more;
2., silicon steel sheet costs an arm and a leg;
3., waste material is difficult for reclaiming.
Patent Office of the People's Republic of China discloses an application for a patent for invention " with the electrical equipment and electrical of soft-magnetic composite material manufacturing " (application number: 03128171.0, publication number CN 1461089A), in the disclosed technical information of the disclosure specification, conducting magnetic component is made of straight iron powder, insulating compound and lubricant, its primary raw material only is a straight iron powder, the material choice narrow range, and price is very expensive, market price is at present up to more than 7000 yuan/ton, cost is higher, and the corresponding production cost of motor, electrical equipment of raw material manufacturing is also very high thereupon thus.Simultaneously, straight iron powder is 80%-90% at the contained proportion of soft magnetic material, because content tool in soft magnetic material of iron plays a very important role, when iron material content is lower than 90%, its magnetic saturation rate can not satisfy the performance requirement of conducting magnetic component far away, directly influence the magnetic property of conducting magnetic component, magnetic permeability is also lower, is difficult to adapt to the product quality demand and the market demand that improve constantly at present.In addition, during its conducting magnetic component product shaping, mixture " need in 1100-1300 ℃ heating furnace sintering 2-3 hour " just can reach designing requirement, therefore, add and must could realize by the higher high-temperature heater of an equipment requirements man-hour, and be heated to the energy cost that such high temperature needs can be very big.Simultaneously, because insulating compound, lubricant content are than great in the conducting magnetic component, dimensional contraction is quite severe during general the shaping, and under this high-temperature technology environmental condition, insulating compound, physical change that lubricant produces and chemical change are bigger, its result can bring variation bigger on the magnetic property of conducting magnetic component and the mechanical property and the distortion of physical dimension when being shaped, and influences crudy.The zinc stearate that lubricant adopted of this application, soap grease or compound sodium lid base grease can not be gasified when being heated to high temperature in sintering process fully, still have part and residue in the conducting magnetic component, influence the serviceability and the forming accuracy of product.In addition, above-mentioned substance behind chemical change, also can residually have other not gasified or the compound of dissolving in sintering furnace, often need clear up, both bothered, expend man-hour again.
Summary of the invention:
Technical problem to be solved by this invention is, overcome existing many defectives in the above-mentioned prior art, provide a kind of and can guarantee the higher magnetic property of conducting magnetic component, mechanical property and forming accuracy, can reach the soft-magnetic composite material of the goal of the invention that reduces cost, easily reclaims again and make the method for conducting magnetic component by it.
The present invention is proposed technical scheme and is by solving the problems of the technologies described above:
A kind of soft-magnetic composite material is characterized in that: described soft-magnetic composite material comprises iron-bearing material, insulating compound and lubricant, and the percentage by weight of each component is: iron-bearing material: 92%-99%; Insulating compound: 0.5%-5%; Lubricant: 0.5%-3%;
Described iron-bearing material is a dusty material, and its iron-holder is 80%-99.8%;
Described powdery iron-containing raw material comprises reduced iron powder, atomized iron powder, carbonyl iron particles and iron alloy powder;
Described reduced iron powder, atomized iron powder, carbonyl iron particles, iron alloy powder, distribution of particles are the 20-500 order;
Described insulating compound adopts the nano-calcium carbonate calcium powder, or ceramic powder, or the magnetic oxide powder;
Described lubricant is a micro mist wax;
A kind of above-mentioned soft-magnetic composite material is made the method for conducting magnetic component, it is characterized in that comprising the steps:
One, mix: is that the lubricant dryness of insulating compound, the 0.5-3% of powdery iron-containing raw material, the 0.5%-5% of 92%-99% is evenly mixed or added the moist even mixing of an amount of solvent by total weight with proportioning;
Two, be shaped: adopt single shaft step 1 gained mixture to be made required form to rigid die press forming, metal injection moulding, power forging shaping, warm-pressing formation, high temperature insostatic pressing (HIP) shaping or cold isostatic compaction method;
Three, solidify: adopt sintering processing to solidify, its curing process is: the conducting magnetic component demoulding after will being shaped, and place in the heating furnace then and heat, its temperature is 800 ℃-1100 ℃, the time is 20-60 minute;
Four, antirust or finishing is handled.
Also can contain binding agent in the soft-magnetic composite material of the present invention, its proportioning is: 0.5%-3%, described binding agent are organic binder bond.
By the method for above-mentioned soft-magnetic composite material manufacturing conducting magnetic component, its feature is comprising the steps:
One, mix: is that the binding agent dryness of lubricant, the 0.5%-3% of insulating compound, the 0.5%-3% of powdery iron-containing raw material, the 0.5%-5% of 92%-99% is evenly mixed or added the moist even mixing of an amount of solvent by total weight with proportioning;
Two, be shaped: adopt single shaft step 1 gained mixture to be made required form to rigid die press forming, metal injection moulding, power forging shaping, warm-pressing formation, high temperature insostatic pressing (HIP) shaping or cold isostatic compaction method;
Three, solidify: adopt normal temperature or low temperature mode to solidify, wherein low-temperature setting technology is: the conducting magnetic component demoulding after will being shaped, and place in the heating furnace then and heat, its temperature is 200 ℃-300 ℃, the time is 1-2 hour.
Four, antirust or finishing is handled.
The present invention's material main component iron-bearing material source is wide, big with respect to the straight iron powder selectable range, cost is more much lower than straight iron powder, direct production cost reduces greatly, and iron-bearing material shared weight ratio in its member is higher than more than 90%, guarantee the magnetic permeability and the magnetic saturation rate of conducting magnetic component effectively, improved the magnetic property and the mechanical property of member.Iron-bearing material of the present invention also can adopt iron alloy powder, and elements such as its interior contained copper, aluminium, silicon, phosphorus can further improve the member magnetic property, increase the soft magnetic material quality.
Because the content proportion of insulating compound, lubricant is little, the shrinkage during product shaping reduces greatly, and dimensional accuracy also is improved.
The conducting magnetic component of product provided by the present invention and technology manufacturing gets final product the defeated and dispersed fragment that becomes under big pressure, be easy to soft-magnetic composite material is separated with copper cash with magnetic separtor, waste material reclaims easily, can not cause any social effects of pollution, can accomplish real environmental protection.
Powder particle of the present invention is classification and distributes, and can guarantee density and uniformity after mixture is suppressed, increases the surface smoothness of member, has further improved the crudy of conducting magnetic component.
Lubricant of the present invention is selected micro mist wax for use, for the flowability of the bulk density of the mixing of soft-magnetic composite material powder, mixture, evenly the knockout press after bulk density, packed density, the compacting is greatly improved compared to prior art, has improved the quality of conducting magnetic component.
Can select as required in the product shaping process of the present invention, even employing high temperature sintering, its maximum temperature also is 1000 ℃, and sintering time is short, has saved the energy, reduced production cost, both solved the technological problems of the aspects such as uniformity in the pressing process, and avoided the defective workmanship that long hot setting brings and cause change on the performance of member, and can make conducting magnetic component reach required magnetic property again, can make it have very high mechanical strength, mechanical property improves.Therefore, the present invention can satisfy the different requirements of various electrical equipment and electricals to conducting magnetic component.
Through overtesting, aspects such as the magnetic property of the conducting magnetic component that the present invention makes, magnetic saturation rate, insulation effect, intensity are approaching with the motor index of silicon steel sheet production, meet of the requirement of different motors fully to magnetic conductance magnetic member, but 50% of the motor cost that cost of the present invention only is former silicon steel sheet to be produced, market prospects are very wide.
Embodiment:
In field of magnetic material, the core material requirement has high saturation flux density, low coercive force, high permeability and zero magnetostriction.Therefore, constitute the composition of magnetic raw material, the corresponding proportioning between each composition, magnetic property and its mechanical property of the goods of the suitable purposes of manufacturing, raising conducting magnetic component are developed new magnetic material and are carried out basic research, seek new application and impel its development, are present this area research personnel's important topic.The invention provides a kind of soft-magnetic composite material that is used to make conducting magnetic component, it comprises iron-bearing material, insulating compound and lubricant, and the percentage by weight of each component is: iron-bearing material: 92%-99%; Insulating compound: 0.5%-5%; Lubricant: 0.5-3%.Selecting for use of said ratio is according to the result of existing market to many-sided combined factors consideration of performance requirement, cost of material, processing technology cost and the machining accuracy etc. of conducting magnetic component and repetition test.The too high physical property and the chemical composition that can influence whole material of insulating compound, lubricant content ratio in whole member crossed low its due effect that then can not produce.
Iron-bearing material is as the base-material of soft magnetic material, it is the topmost raw material that constitutes conducting magnetic component, can adopt powdered metallurgical material with broad development prospect, its source is wide, it is simple to be processed into the Processes and apparatus that member adopts, cost is low, function admirable, have characteristics such as high-purity, low impurity, high conformity, compressibility and good moldability, iron-bearing material of the present invention is the proportioning height in its total weight, iron-holder is 80%-99.8%, organically combines by insulating compound, lubricant with corresponding proportion, can reach needed magnetic property of conducting magnetic component and mechanical strength.
Described powdery iron-containing raw material can comprise reduced iron powder, atomized iron powder or carbonyl iron particles, also can adopt the ferroalloy material, and wherein reduced iron powder can adopt reduced iron powder and secondary reduction iron powder, and price only is 2/5ths of a straight iron powder.
Reduced iron powder, atomized iron powder, carbonyl iron particles are high-purity, high-grade iron-based material, the iron-holder height, and saturation induction density very low (0.5T following), but permeability is than higher, and resistivity is very high, therefore is very beneficial for reducing eddy current loss.
Iron alloy powder contains elements such as silicon, aluminium, phosphorus, nickel, copper, molybdenum, can increase the intensity and the hardness of material, improves its mechanical property, and these elements can increase the magnetic permeability and the magnetic flux density of conducting magnetic component simultaneously, further improve magnetic property.
Described powdery iron-containing material granule is the 20-500 order and distributes, and can mix at above-mentioned scope internal classification by proper proportion, and fully the gap between the powder filler particle has better uniformity and higher density to guarantee member.
The interpolation of insulating compound can make and be insulated agent between the soft-magnetic composite material powder particle and keep apart, and it is saturated to avoid preventing that magnetic bias because of direct current signal from causing member to be magnetized to, and reduces its magnetic property.
Insulating compound of the present invention can adopt nano-calcium carbonate or ceramic powder or magnetic oxide powder.
Described nano-calcium carbonate is a kind of novel ultrafine solids material.Particle diameter is between 1-100 nanometer (nm), because ultra-fineization of nanometer grade calcium carbonate particle, its crystal structure and surface electronic structure change, the quantum size effect that ordinary calcium carbonate did not have, small-size effect, skin effect and macroscopic quantum effect have been produced, it is thin and even to have particle diameter, narrowly distributing, specific area is big, surface activity and good dispersion, the surface energy height, comparing with conventional material at aspects such as magnetic, catalytic, photo-thermal resistance and fusing points and to demonstrate superior performance, is a kind of good insulation agent.
Described ceramic powder is a kind of high-strength, high-modulus, high performance material, high temperature resistant, acid and alkali-resistance, fire-retardant and have high tenacity, also be a kind of better and can high voltage bearing insulating material.
Described magnetic oxide powder has good adhesive force, hardness, chemical resistance and physical and mechanical properties, and has good insulation performance.
Adopt lubricant can reduce extruding force in the conducting magnetic component, make the pulverulent material good fluidity, the member wall thickness is even during compacting, and stripping force is little, can improve the surface smoothness of press members.But lubricant select for use and addition for the flowability of the bulk density of the mixing of soft-magnetic composite material powder, mixture, evenly the knockout press after bulk density, packed density, the compacting has very big influence, lubricant of the present invention adopts micro mist wax.Micro mist wax is a kind of hard and crisp LCFA diamides, be dystectic organic hard synthetic wax, water insoluble, be slightly soluble in the lower boiling organic solvent, be dissolved in high temperature, the high boiling solvent, have good lubricating property and have good pyrolysis weight behavior in the sintering dewaxing stage.Micro mist wax in sintering, be heated to 600 ℃ almost completely the gasification and do not stay residue in sintering furnace, guaranteed the original quality of conducting magnetic component preferably.
The present invention also can add an amount of bonding agent in above-mentioned weight proportion, its proportioning is 0.5%-3%, and bonding agent can adopt organic binder bond.The employing of bonding agent both can have been strengthened the connection between the powder particle, can make again between the powder particle to isolate mutually, and it is saturated to avoid conducting magnetic component to be magnetized, and reduces its magnetic property.
Embodiment one:
A kind of soft-magnetic composite material that is used to make conducting magnetic component that present embodiment provided, the reduced iron powder by 95%, 3% nano-calcium carbonate calcium powder, 2% micro mist wax are formed.
The method of the conducting magnetic component of the soft-magnetic composite material manufacturing that is provided by this embodiment is:
One, mix: is that reduced iron powder of powdery of 95%, 3% nano-calcium carbonate calcium powder, 2% micro mist wax evenly mix by total weight with proportioning.
Two, be shaped: the mixed powder that stirs is loaded in the shaping dies, adopts the warm-pressing formation mode to be shaped, then pressed compact is deviate from from mould.
Warm-pressing formation is present powder metallurgy New Forming Process, and it is with powder and mould is the highest is heated to about 150 ℃, just can realize that required input is little so can add heating system on the ordinary powder press.And the green strength height that adopts warm-pressing technology to produce, the machine work that can directly add again, and pressing pressure and ejection pressure are all lower, thus die life height, can reduce production costs greatly.Simultaneously, adopt warm-pressing technology can improve the parts green density, can make the green density of iron powder parts reach 7.25~7.45g/cm 3, compare with traditional handicraft and to have improved 0.15~0.3g/cm 3, product has high strength.Compare with conventional moulded technology, the fatigue strength of part improves 10-40%, ultimate tensile strength improves 10%, sintered state ultimate tensile strength 〉=1200MPa, the ejection pressure of pressed compact low (reducing more than 30%), compact strength height (improving 125~200%), and elastic after effect little (0.1~0.16%), sintering shrinkage few (0.025~0.08%), compacting back powder density is even: general pressed compact each several part density contrast can reduce by 0.1~0.2g/cm3.Therefore, the made properties of product of warm-pressing technology are much better than prior art.
Three, solidify: pressed compact is placed the controlled atmosphere gas stove, carry out high temperature sintering and solidify.The conventional high-temperature sintering temperature is generally more than 1100 ℃, and the time, the present invention was through overtesting more than at least 2 hours, pressed compact high temperature sintering temperature is 800 ℃~1100 ℃, and the time is 25-60 minute, can reach the desired properties requirement, save the energy, also reduced the member manufacturing cost.
In the practical application, conducting magnetic component also can be formed by stacking by multi-disc, can avoid producing eddy current loss.The combination of the multi-disc of conducting magnetic component realizes by the riveted joint mode in the prior art, add and must on member, stamp location hole man-hour, and then riveted joint mutually.This method can cause being connected not closely between sheet and the sheet, reduces crudy, can reduce the mechanical property of member simultaneously.The present invention is behind monolithic conducting magnetic component press forming, can be with the superimposed sintering together of polylith, utilize the crystallization between each chip bonding interface, can reach the effect identical with welding, strengthened the adhesive strength between sheet and the sheet, guarantee that it is superimposed tight, can not reduce the member mechanical strength, also can increase the aesthetic feeling of combination outer surface simultaneously.
Four, after the cooling, member is taken out in high temperature furnace, carry out antirust to the conducting magnetic component surface again or the finishing processing.
Above-mentioned steps three adopts high temperature curing process, can guarantee the mutual bonding force of conducting magnetic component behind the press forming, can improve insulation property simultaneously.
Embodiment two:
A kind of soft-magnetic composite material of making conducting magnetic component that present embodiment provided is used for the conducting magnetic component electrical equipment and electrical low to requirement of strength.It is to be formed by carbonyl iron particles, insulating compound, lubricant, the mutual proportioning of binding agent, and the percentage by weight of each component is: secondary reduction iron powder: 94%; Ceramic powder 3%; Micro mist wax 1%, organic binder bond 2%.
The method of the conducting magnetic component of the soft-magnetic composite material manufacturing that is provided by present embodiment is:
One, mix: the secondary reduction iron powder with 94%, 3% ceramic powder, 1% micro mist wax mix, and add 2% organic binder bond then;
Two, be shaped: then powder is put into mould, and and mould be heated to together and carry out the rigid mould compacting about 80-150 ℃, can be pressed into the thick workpiece of 5-20mm by dimensional requirement;
Three, solidify: the conducting magnetic component that is shaped is warmed to 200 ℃-300 ℃, conducting magnetic component is cured, can guarantee the mutual bonding force of conducting magnetic component behind the press forming, get rid of gas in it.After the demoulding, component surface is done finishing and antirust processing.
The present embodiment conducting magnetic component adopts the low temperature pressing process, can reach the required magnetic property of the low slightly conducting magnetic component of requirement of strength, has certain mechanical strength.Like this, this soft-magnetic composite material just can satisfy the different requirements of various electrical equipment and electricals to conducting magnetic component.
The conducting magnetic component of manufacturing of the present invention gets final product the defeated and dispersed fragment that becomes under big pressure, be easy to soft-magnetic composite material is separated with copper cash with magnetic separtor, and waste material is easy to reclaim, and meets present environmental requirement.
Material provided by the invention and technology are applicable to that induction machine and the following string of 1000W made more than the 10W hit motor, capacitor motor.

Claims (10)

1. soft-magnetic composite material, it is characterized in that: described soft-magnetic composite material comprises iron-bearing material, insulating compound and lubricant, the percentage by weight of each component is: iron-bearing material: 92%-99%; Insulating compound: 0.5%-5%; Lubricant: 0.5%-3%.
2. soft-magnetic composite material according to claim 1 is characterized in that: also contain binding agent in the described soft-magnetic composite material, its proportioning is: 0.5%-3%.
3. soft-magnetic composite material according to claim 1 is characterized in that: described iron-bearing material is a dusty material, and its iron-holder is 80%-99.8%.
4. a kind of soft-magnetic composite material according to claim 3 is characterized in that: described powdery iron-containing raw material comprises reduced iron powder, atomized iron powder, carbonyl iron particles and iron alloy powder.
5. according to claim 1 or 2 or 3 described a kind of soft-magnetic composite materials, it is characterized in that: described insulating compound adopts the nano-calcium carbonate calcium powder, or ceramic powder, or the magnetic oxide powder.
6. according to claim 1 or 2 or 3 described a kind of soft-magnetic composite materials, it is characterized in that: described lubricant is a micro mist wax.
7. a kind of soft-magnetic composite material according to claim 2 is characterized in that: described binding agent is an organic binder bond.
8. a kind of soft-magnetic composite material according to claim 4 is characterized in that: described reduced iron powder, atomized iron powder, carbonyl iron particles, iron alloy powder, distribution of particles are the 20-500 order.
9. the method by the described soft-magnetic composite material manufacturing of claim 1 conducting magnetic component is characterized in that comprising the steps:
One, mix: is that the lubricant dryness of insulating compound, the 0.5-3% of powdery iron-containing raw material, the 0.5%-5% of 92%-99% is evenly mixed or added the moist even mixing of an amount of solvent by total weight with proportioning;
Two, be shaped: adopt single shaft step 1 gained mixture to be made required form to rigid die press forming, metal injection moulding, power forging shaping, warm-pressing formation, high temperature insostatic pressing (HIP) shaping or cold isostatic compaction method;
Three, solidify: adopt sintering processing to solidify, its curing process is: the conducting magnetic component demoulding after will being shaped, and place in the heating furnace then and heat, its temperature is 800 ℃-1100 ℃, the time is 20-60 minute;
Four, antirust or finishing is handled.
10. the method by the described soft-magnetic composite material manufacturing of claim 2 conducting magnetic component is characterized in that comprising the steps:
One, mix: is that the binding agent dryness of lubricant, the 0.5%-3% of insulating compound, the 0.5%-3% of powdery iron-containing raw material, the 0.5%-5% of 92%-99% is evenly mixed or added the moist even mixing of an amount of solvent by total weight with proportioning;
Two, be shaped: adopt single shaft step 1 gained mixture to be made required form to rigid die press forming, metal injection moulding, power forging shaping, warm-pressing formation, high temperature insostatic pressing (HIP) shaping or cold isostatic compaction method;
Three, solidify: adopt normal temperature or low temperature mode to solidify, wherein low-temperature setting technology is: the conducting magnetic component demoulding after will being shaped, and place in the heating furnace then and heat, its temperature is 200 ℃-300 ℃, the time is 1-2 hour;
Four, antirust or finishing is handled.
CNB2005100316147A 2005-05-27 2005-05-27 Soft-magnetic composite material and process for making magnetic conduction component by using same Expired - Fee Related CN100380537C (en)

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