CN102666431B - 铁素体磁性材料、铁素体磁铁、铁素体烧结磁铁 - Google Patents
铁素体磁性材料、铁素体磁铁、铁素体烧结磁铁 Download PDFInfo
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- CN102666431B CN102666431B CN201180004147.2A CN201180004147A CN102666431B CN 102666431 B CN102666431 B CN 102666431B CN 201180004147 A CN201180004147 A CN 201180004147A CN 102666431 B CN102666431 B CN 102666431B
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
-
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Abstract
提供可获得保持高Br和HcJ并且具有高Hk/HcJ的永久磁铁的铁素体磁性材料,以及含有该铁素体磁性材料的铁素体磁铁和铁素体烧结磁铁。铁素体磁性材料、含有该铁素体磁性材料的铁素体磁铁和铁素体烧结磁铁的特征在于,所述铁素体磁性材料具有六方晶结构的铁素体相构成的主相,具有Ca1-w-x-yRwSrxBayFezMm表示的金属元素组成,满足0.25<w<0.5、0.01<x<0.35、0.0001<y<0.013、y<x、8.7<z<9.9、1.0<w/m<2.1、0.017<m/z<0.055,至少含有Si成分作为副成分,将上述铁素体磁性材料中上述Si成分换算为SiO2的含量y1质量%在Y轴表示,将上述z与m的合计量x1在X轴表示,则x1和y1的关系在具有上述X轴和Y轴的X-Y坐标中规定的4个点包围的范围内。
Description
技术领域
本发明涉及铁素体(ferrite,铁氧体)磁性材料,以及含有该铁素体磁性材料的铁素体磁铁和铁素体烧结磁铁。
背景技术
作为氧化物构成的永久磁铁的材料,已知有六方晶系M型(磁铅石型)Sr铁素体或Ba铁素体。这些铁素体构成的铁素体磁性材料以铁素体烧结体或粘结磁铁的形式作为永久磁铁提供。近年来,伴随着电子部件的小型化、高性能化,对于铁素体磁性材料构成的永久磁铁也日益要求在小型的同时具有高磁特性。
永久磁铁的磁特性的指标通常采用剩余磁通密度(Br)和矫顽力(HcJ),它们越高则评价为越具有高磁特性。以往,从提高永久磁铁的Br和HcJ的角度考虑,进行了使铁素体磁性材料中含有规定的元素等的改变组成的研究。
例如专利文献1中公开了一种氧化物磁性材料,它是在M型Ca铁素体中至少含有La、Ba和Co,由此可得到具有高Br和HcJ的铁素体烧结磁铁。
另外,专利文献2中公开了一种氧化物磁性材料,它是在M型Ca铁素体中至少含有La、Sr和Co,由此可得到具有高Br和HcJ的铁素体烧结磁铁。并且在专利文献3中公开了一种烧结磁铁,它是在M型Sr铁素体中含有Sr、La和Co,由此具有高Br和HcJ。
现有技术文献
专利文献
专利文献1:日本特许第4078566号公报
专利文献2:国际公开第2007/077811号小册子
专利文献3:日本特许第3163279号公报
发明内容
发明要解决的课题
如上所述,为了良好地获得Br和HcJ两者,人们尝试将添加到主要组成中的元素的组合进行各种改变,但是对于哪种添加元素的组合可以获得高磁特性尚未明确。
另外,优选永久磁铁除了具有高Br和HcJ之外,磁化为Br的90%时磁场的值(Hk)相对于HcJ的比率、即所谓的矩形比(角型比,Hk/HcJ)也高。Hk/HcJ高,则外部磁场或温度变化导致的退磁减小,可获得稳定的磁特性。
因此,在使用铁素体磁性材料的永久磁铁中,优选在获得高Br和HcJ的同时还可获得优异的Hk/HcJ。但是,若任意一种磁特性提高则其它磁特性降低等,获得可得到具有上述三种磁特性的永久磁铁的铁素体磁性材料在以往绝不是件容易的事情。
并且,为了提高Br,有效的方法是:使构成铁素体相的晶体粒子的易磁化轴(为M型铁素体时,为c轴方向)的方向一致,即提高易磁化轴的取向性,以获得各向异性化。但是,如果提高取向性,则在M型铁素体中,有晶体粒子容易沿着与易磁化轴垂直方向的难磁化轴方向生长的倾向,因此,难磁化轴方向的平均晶体粒径与易磁化轴方向的平均晶体粒径之比所示的长宽比容易提高。长宽比提高,则容易在晶体粒子内受到退磁场的影响。另外,难磁化轴方向的平均晶体粒径增大,这显示形成单磁畴粒子(为M型铁素体时,约为1μm)的晶体粒子数减少。由于这些影响,HcJ降低,难以与高Br同时实现。
因此,本发明针对上述情况而成,其目的在于提供可获得保持高Br和HcJ、并且具有高Hk/HcJ的永久磁铁的铁素体磁性材料,以及含有所述铁素体磁性材料的磁铁。
解决课题的手段
为实现上述目的,本发明的铁素体磁性材料是具有由六方晶结构的铁素体相构成的主相的铁素体磁性材料,其特征在于:该铁素体磁性材料具有下式(1)所示的金属元素的组成:
Ca1-w-x-yRwSrxBayFezMm (1)
不过,式(1)中,R为选自稀土类元素(包含Y)和Bi的至少一种元素并至少含有La,M为选自Co、Mn、Mg、Ni、Cu和Zn的至少一种元素并至少含有Co,
式(1)中,w、x、y、z和m满足下式(2)、(3)、(4)、(5)、(6)、(7)和(8):
0.25<w<0.5 (2)
0.01<x<0.35 (3)
0.0001<y<0.013 (4)
y<x (5)
8.7<z<9.9 (6)
1.0<w/m<2.1 (7)
0.017<m/z<0.055 (8)
至少含有Si成分作为副成分,
将上述铁素体磁性材料中的该Si成分换算为SiO2的含量y1在Y轴表示,将上述z与m的合计量x1在X轴表示,则x1与y1的关系在由具有上述X轴和Y轴的X-Y坐标中的4个点a(8.9,1.2)、b(8.3,0.95)、c(10.0,0.35)和d(10.6,0.6)所包围的范围内。
上述本发明的铁素体磁性材料由上式(1)表示,各元素满足式(2)-(8)的条件,同时进一步含有Si成分作为副成分,将上述铁素体磁性材料中的上述Si成分换算为SiO2的比率y1质量%在Y轴表示,将上述z与m的合计量x1在X轴表示,则x1与y1的关系在由具有上述X轴和Y轴的X-Y坐标中的4个点a(8.9,1.2)、b(8.3,0.95)、c(10.0,0.35)和d(10.6,0.6)所包围的范围内,由此形成不仅具有高Br和HcJ、还具有高Hk/HcJ的铁素体磁铁或铁素体烧结磁铁。
优选在上述铁素体磁铁或铁素体烧结磁铁中,通过X射线衍射测定求出的晶体取向度Or(f)=∑(001)/∑(hk1)为0.9以上。
优选在将构成上述铁素体磁铁或铁素体烧结磁铁的晶体粒子沿与c轴方向平行的面切断所得的剖面中,分别求出通过上述各晶体粒子的剖面重心的粒径最大值和最小值,当规定数目以上的晶体粒子中、上述粒径的最大值和最小值的平均分别设为L(μm)、S(μm)时,上述L和S满足下式(9)和(10)。
L≤1.4 (9)
L/S≤2.4 (10)
附图简述
[图1]图1是,对于本申请的实施例的各试样,将铁素体磁性材料中的上述Si成分换算为SiO2的含量y1质量%在Y轴表示、将上述z和m的合计量x1在X轴表示时,将x1与y1的关系显示在具有X轴和Y轴的X-Y坐标中的图。
[图2]图2是晶体粒子的剖面图,该图用于说明构成本发明的一个实施方案的铁素体烧结磁铁的晶体粒子的晶体粒径与长宽比的测定方法。
[图3]图3(A)是本发明的实施例的铁素体烧结磁铁的剖面SEM照片,图3(B)是本发明的比较例的铁素体烧结磁铁的剖面SEM照片。
[图4]图4是本发明的一个实施方案的烧结磁铁制造方法中使用的磁场注射成型机的主要部分剖面图。
具体实施方案
以下说明本发明的实施方案。
(铁素体烧结磁铁)
构成本发明的一个实施方案的铁素体烧结磁铁的铁素体磁性材料具有铁素体相构成的主相,该铁素体相具有六方晶结构。上述铁素体相优选为磁铅石型(M型)铁素体(以下称为“M型铁素体”)。尚需说明,特别将磁铅石型(M型)铁素体构成的主相称为“M相”。这里,当铁素体烧结磁铁含有“主相(晶体粒子)”和“晶界部分”时,“铁素体相构成的主相”通常是指该主相为铁素体相。主相在烧结体中所占的比例优选为95体积%以上。
如前所述,构成铁素体烧结磁铁的铁素体磁性材料是烧结体的形态,具有含晶体粒子(主相)和晶界的结构。该烧结体中的晶体粒子的平均晶体粒径优选为1.4μm以下,更优选0.5-1.4μm。由于具有上述平均晶体粒径,可容易地获得高HcJ。尚需说明,这里所述的平均晶体粒径是M型铁素体的烧结体中的晶体粒子在难磁化轴(a轴)方向的粒径的算术平均值。铁素体磁性材料的烧结体的晶体粒径可通过扫描式电子显微镜测定。
本实施方案的铁素体磁性材料具有下式(1)所示的金属元素的组成。
Ca1-w-x-yRwSrxBayFezMm …(1)
这里,式(1)中,R为选自稀土类元素(包含Y)和Bi的至少一种元素并至少含有La,M为选自Co、Mn、Mg、Ni、Cu和Zn的至少一种元素并至少含有Co。
式(1)中,w、x、y、z和m分别表示R、Sr、Ba、Fe和M的原子比率,满足所有下式(2)、(3)、(4)、(5)、(6)、(7)和(8):
0.25<w<0.5 (2)
0.01<x<0.35 (3)
0.0001<y<0.013 (4)
y<x (5)
8.7<z<9.9 (6)
1.0<w/m<2.1 (7)
0.017<m/z<0.055 (8)
另外,铁素体磁性材料至少含有Si成分作为上述金属元素组成以外的副成分,如图1所示,将上述铁素体磁性材料中的上述Si成分的换算为SiO2的含量y1质量%在Y轴表示、将上述z与m的合计量x1在X轴表示时,x1与y1的关系在具有上述X轴和Y轴的X-Y坐标中的4个点a(8.9,1.2)、b(8.3,0.95)、c(10.0,0.35)和d(10.6,0.6)所包围的范围内。
另外,氧的组成比受各金属元素的组成比、各元素(离子)的价数影响,在晶体内增减以保持电中性。另外,在后述的烧结工序时,若使烧结气氛为还原性气氛,则可能发生氧缺失。
以下对上述铁素体磁性材料的组成更详细地进行说明。
构成上述铁素体磁性材料的金属元素的组成中,优选Ca的原子比率(1-w-x-y)超过0.25但低于0.59。若Ca的原子比率过小,则铁素体磁性材料可能无法形成M型铁素体。
另外,除了α-F2O3等非磁性相的比例增加之外,R过量则生成正铁氧体等非磁性的异相,磁特性(特别是Br和HcJ)有降低倾向。另一方面,若Ca的原子比率过大则可能无法形成M型铁素体,并且CaFeO3-x等非磁性相增多,磁特性可能降低。
本实施方案的铁素体烧结磁铁除了如后所述含有SiO2作为副成分之外,还可进一步含有其它副成分。例如,首先可以含有Ca成分作为副成分。但是,如上所述,本实施方案的铁素体烧结磁铁含有Ca作为构成主相铁素体相的成分。因此,含有Ca作为副成分时,例如由烧结体分析得到的Ca量是主相与副成分的总量。即,使用Ca成分作为副成分时,通式(1)中的Ca的原子比率(1-w-x-y)是也包含副成分的值。原子比率(1-w-x-y)的范围是基于烧结后分析的组成而特别规定的,因此,可适用于含有和不含有Ca成分作为副成分的两种情形。
R所示的元素至少含有La,除此之外,作为La以外的元素优选选自稀土类元素(含有Y)和Bi的至少一种,更优选选自稀土类元素的至少一种。不过,R只含有La的情况,从提高各向异性磁场的角度考虑特别优选。
构成上述铁素体磁性材料的金属元素组成中,R的原子比率(w)超过0.25但低于0.5,若在该范围内则可良好地获得Br和HcJ以及Hk/HcJ。R的原子比率过小,则铁素体磁性材料中的M的固溶量不足,Br和HcJ降低。另一方面,过大则产生正铁氧体等非磁性的异相,Hk/HcJ降低,难以获得实用的磁铁。从上述角度考虑,R的原子比率优选为0.3以上但低于0.5,更优选0.3-0.45。
Sr的原子比率(x)超过0.01但低于0.35,若在该范围内则可以满足良好的Br、HcJ和Hk/HcJ。Si的原子比率过小,则Ca和/或La的比率增大,Hk/HcJ降低。另一方面,Sr的原子比率过大,则Br和HcJ不足。从以上角度考虑,Sr的原子比率优选为0.05-0.25,更优选0.1-0.2。
Ba的原子比率(y)超过0.0001但低于0.013,若在该范围内则可以满足良好的Br、HcJ和Hk/HcJ。Ba的原子比率过小,则无法获得充分的Hk/HcJ提高效果。另一方面,过大则Br和HcJ都不合适地降低。由以上角度考虑,Ba的原子比率优选为0.0004-0.01。
另外,Sr的原子比率(x)和Ba的原子比率(y)满足y<x的关系。这样,通过使Sr的原子比率大于Ba的原子比率,除获得良好的Br之外,还容易获得充分高的FHk/HcJ。
Fe的原子比率(z)超过8.7但低于9.9,通过在该范围内,可以满足良好的Br、HcJ和Hk/HcJ。Fe的原子比率过小或过大,Br和HcJ都不合适地降低。Fe的原子比率优选为8.8-9.6。
M所示的元素至少含有Co,除此之外,作为Co以外的元素优选为选自Mn、Mg、Ni、Cu和Zn的至少一种,更优选为选自Mn、Ni和Zn的至少一种。不过,M只含有Co的情况,从提高各向异性磁场的角度考虑特别优选。
构成铁素体磁性材料的金属元素的组成,关于M的原子比率(m),首先满足m/z超过0.017但低于0.055的条件。还满足w/m超过1.0但低于2.1的条件。通过满足这些条件,可以获得良好的Br、HcJ和Hk/HcJ。M的原子比率过小时,无法获得良好的Br和HcJ,特别是Co的比率过小,则无法获得良好的HcJ。另一方面,M的比率过大时,Br和HcJ更倾向于降低。
由这些角度考虑,m/z优选为0.02-0.035。而w/m优选为1.2-1.9,更优选1.4-1.8。
本发明中的铁素体磁性材料除上述金属元素的组成之外还含有后述的副成分。副成分可以在铁素体磁性材料的主相和晶界的任一中含有。在铁素体磁性材料中,全体中副成分以外的均是主要组成。从获得充分的磁特性的角度考虑,铁素体磁性材料中,主相的含有比例优选为90质量%以上,更优选95-100质量%。
本实施方案的铁素体磁性材料至少含有Si(硅)成分作为副成分。这里,Si成分包含Si原子本身和含Si的化合物(SiO2等)两者。含Si的化合物只要具有含有Si的组成即可,没有特别限定,例如可举出SiO2、Na2SiO3、SiO2·nH2O等。铁素体磁性材料通过含有Si成分,使烧结性良好,还可将烧结体的晶体粒径适度调节,形成磁特性得到良好控制的铁素体烧结磁铁。结果,可良好保持Br和HcJ,同时可获得高Hk/HcJ。
如图1所示,本实施方案的铁素体磁性材料中,将上述铁素体磁性材料中的上述Si成分换算为SiO2的比率y1质量%表示在Y轴,将上述z与m的合计量x1表示在X轴时,x1与y1的关系在具有上述X轴和Y轴的X-Y坐标中的4个点a(8.9,1.2)、b(8.3,0.95)、c(10.0,0.35)和d(10.6,0.6)所包围的范围内。
通过使x1和y1、即Si成分的比率与z和m的合计量y1的关系在该区域内,结果可获得良好的Br、HcJ以及Hk/HcJ。Si成分的含量过多,则作为非磁性成分的Si成分在铁素体烧结磁铁中大量含有,因此磁特性(特别是Br)有降低倾向。另一方面,Si成分过少,也无法获得上述的良好的效果,HcJ有降低倾向。
在本发明的铁素体磁性材料中,Si成分的含量是所有Si成分的合计,换算为SiO2优选为0.35-1.2质量%,更优选0.4-1.1质量%。Si成分为上述含量,则可获得高HcJ。
铁素体磁性材料含有上述金属元素组成以及至少含有Si成分的副成分,铁素体磁性材料的组成可通过荧光X射线定量分析来测定。另外,主相的存在可通过X射线衍射或电子射线衍射来确认。
本实施方案的铁素体磁性材料可含有Si成分以外的成分作为副成分。作为其它副成分例如可以具有Al和/或Cr。由此,铁素体烧结磁铁的HcJ有提高倾向。从获得良好的HcJ的提高效果考虑,Al和/或Cr的含量相对于铁素体磁性材料全体,换算为Al2O3或Cr2O3合计优选0.1质量%以上。不过这些成分可能使铁素体烧结磁铁的Br降低,因此,从获得良好的Br的角度考虑,优选为3质量%以下。
另外,还可以例如以B2O3的形式含有硼B作为副成分。通过含有B,在获得铁素体磁性材料时的预烧温度或在获得含有铁素体磁性材料的烧结体时的烧结温度可以降低,可以生产性良好地获得铁素体烧结磁铁。不过,B过多则铁素体烧结磁铁的饱和磁化可能降低,因此B的含量相对于铁素体磁性材料全体,作为B2O3优选为0.5质量%以下。
本实施方案的铁素体磁性材料可以进一步以氧化物的形式含有Ga、Mg、Cu、Mn、Ni、Zn、In、Li、Ti、Zr、Ge、Sn、V、Nb、Ta、Sb、As、W、Mo等作为副成分。它们的含量换算为各原子的化学计量组成的氧化物,优选氧化镓为5质量%以下,氧化镁为5质量%以下,氧化铜为5质量%以下,氧化锰为5质量%以下,氧化镍为5质量%以下,氧化锌为5质量%以下,氧化铟为3质量%以下,氧化锂为1质量%以下,氧化钛为3质量%以下,氧化锆为3质量%以下,氧化锗为3质量%以下,氧化锡为3质量%以下,氧化钒为3质量%以下,氧化铌为3质量%以下,氧化钽为3质量%以下,氧化锑为3质量%以下,氧化砷为3质量%以下,氧化钨为3质量%以下,氧化钼为3质量%以下。不过,含有它们多种的组合时,为避免磁特性的降低,优选使其合计为5质量%以下。
本实施方案的铁素体磁性材料优选不含有碱金属元素(Na、K、Rb等)作为副成分。碱金属元素有容易使磁铁1的饱和磁化降低的倾向。不过,也有碱金属元素在例如为获得铁素体磁性材料而使用的原料中含有的情况,如果是这类不可避免地含有的程度,则可以在铁素体磁性材料含有。对磁特性没有大的影响的碱金属元素的含量为3质量%以下。
(铁素体烧结磁铁的晶体取向度)
对于本实施方案的铁素体烧结磁铁,通过X射线衍射(XRD)测定求出的晶体取向度Or(f)=∑(001)/∑(hkl)优选为0.9以上,更优选0.92以上。
这里,对于晶体取向度Or(f)的测定方法进行说明。首先,将例如圆板或圆柱状的铁素体烧结磁铁的一个面研磨平滑,对于该平滑研磨面进行XRD测定,获得衍射图,识别来自铁素体烧结磁铁的衍射峰。并由该衍射峰的面指数和峰强度求出铁素体烧结磁铁的晶体学取向度(X射线取向度)。
尚需说明,本发明中,铁素体烧结磁铁的晶体取向度Or(f)=ΣI(00L)/∑I(hkL),该式的(00L)是表示(004)、(006)等晶体结构中c面(与c轴垂直的面)的总称,∑I(00L)表示归属于(00L)面的所有峰强度的合计。另外,(hkL)表示所检测出的所有的衍射峰,∑I(hkL)是这些峰强度的合计。
另外,(00L)所表示的c面是与本实施方案的铁素体烧结磁铁中的易磁化轴垂直的面。(00L)面的峰强度合计越高,即Or(f)=∑I(00L)/∑I(hkL)越高,则晶体学上的易磁化轴越一致,Br提高。
(铁素体烧结磁铁的晶体粒子)
如图2所示,本实施方案的铁素体烧结磁铁的剖面由椭圆状的晶体粒子构成。本实施方案中,在将构成上述铁素体烧结磁铁的晶体粒子沿与c轴方向平行的面切断的剖面中,分别求出通过上述各晶体粒子的剖面重心的粒径最大值和最小值,当规定数目以上的晶体粒子的平均分别设为L(μm)、S(μm)时,优选上述L和S满足下式(9)和(10)。
L≤1.4 (9)
L/S≤2.4 (10)
L的范围更优选L≤1.37,进一步优选0.6≤L≤1.37。另外,L/S的范围更优选L/S≤2.35,进一步优选1.7≤L/S≤2.35。
上述L/S是被称为长宽比的参数。在M型铁素体中,取向度升高,则晶体粒子倾向于容易在相对于易磁化轴(六方晶结构的c轴,图2中L的方向)垂直方向的难磁化轴(六方晶结构的a轴,图2中S的方向)方向上生长。因此,难磁化轴方向的平均晶体粒径与易磁化轴方向的平均晶体粒径之比所示的长宽比容易升高。而长宽比升高则在晶体粒子内容易受到退磁场的影响。另外,难磁化轴方向的平均晶体粒径增大,这表示形成单磁畴粒子(为M型铁素体时,约1μm)的晶体粒子数减少。由于这些影响,HcJ降低,难以与高Br同时实现。
但是,本实施方案的铁素体磁性材料中,通过满足上式(9)和(10)所示的条件,可以保持高Br和HcJ。
以下,参照图2和图3对上述平均最大粒径L和上述平均最小粒径S进行详细说明。如上所述,M型铁素体在c轴方向具有易磁化轴。因此,为了测定平均最大粒径L和平均最小粒径S,首先切取与铁素体烧结磁铁的c轴方向平行的剖面。接着,在该剖面实施镜面研磨和氢氟酸蚀刻处理。通过蚀刻处理除去晶体的晶界部分,使晶体粒子容易观察。接着,通过扫描式电子显微镜(SEM)观察该剖面,获得与c轴方向平行的粒子剖面图像。所得剖面图像的一个例子示于图3(a)。
接着,对晶体粒子剖面图像进行图像分析处理,对于各晶体粒子分别测定通过该晶体粒子剖面重心的粒径最大值和最小值。本实施方案中,如图2所示,分别导出通过一个晶体粒子20的粒子剖面重心J的粒径的最大值—最大粒径1(μm),和通过重心J的粒径最小值—最小粒径s(μm)。然后对晶体粒子的规定数目计算上述最大粒径和最小粒径的算术平均值,分别定义为平均最大粒径L和平均最小粒径S。尚需说明,用于求出平均的晶体粒子的规定数目优选为500个以上。
另外,本实施方案的含有铁素体磁性材料的磁铁并不限于上述铁素体烧结磁铁,例如可举出铁素体磁性材料的粉末通过粘结剂结合而成的粘结磁铁等。
对于粘结磁铁,上述铁素体磁性材料的条件只要在铁素体磁性材料的粉末中得到满足即可。构成铁素体磁性材料的粉末的一次粒子的平均粒径没有特别限定,优选为2μm以下,更优选1.5μm以下,进一步优选0.1-1μm。该平均粒径过大则粉末中多磁畴粒子的比例升高,HcJ可能降低。而平均粒径过小则由于热扰动导致磁性降低,或者在磁场中成型时的取向性或成型性变差。
粘结剂可举出丁腈橡胶(例如NBR橡胶)、聚氯乙烯、聚酰胺树脂(例如尼龙6、尼龙12(以上为注册商标))等。
(铁素体烧结磁铁的制造方法)
在以下实施方案中给出了含有铁素体磁性材料的铁素体烧结磁铁的制造方法的一个例子。本实施方案中,铁素体烧结磁铁可经由配合工序、预烧工序、粉碎工序、成型工序和烧结工序制造。另外,粉碎工序和成型工序之间可含有微粉碎浆料的干燥工序、混炼工序,成型工序与烧结工序之间可含有脱脂工序。以下对各工序进行说明。
<配合工序>
配合工序中,配合铁素体磁性材料的原料,获得原料混合物。首先,铁素体磁性材料的原料可举出含有构成该材料的元素中的1种或2种以上的化合物(原料化合物)。原料化合物例如适合地为粉末状。原料化合物可举出各元素的氧化物或者可通过烧结形成氧化物的化合物(碳酸盐、氢氧化物、硝酸盐等)。例如可例举:SrCO3、La(OH)3、Fe2O3、BaCO3、CaCO3和Co3O4等。例如从可均匀配合的角度考虑,原料化合物的粉末的平均粒径优选为0.1-2.0μm左右。
另外,铁素体磁性材料中的Si成分的原料可举出SiO2,不过只要是含有Si的化合物等即可,没有特别限定。另外,原料粉末中也可根据需要配合其它副成分的原料化合物(元素单质、氧化物等)。
配合例如可如下进行:称量各原料使其可获得所需的铁素体磁性材料的组成并混合后,使用湿式磨碎机、球磨机等进行0.1-20小时左右的混合、粉碎处理。
尚需说明,该配合工序中,无需将所有原料混合,可以将一部分在后述的预烧后添加。例如副成分Si的原料(例如SiO2)或金属元素组成的构成元素Ca的原料(例如CaCO3)也可以在后述的预烧后,在粉碎(特别是在微粉碎)工序中添加。可调节添加的时期,以容易获得所需的组成和磁特性。
<预烧工序>
预烧工序中,将在配合工序中得到的原料粉末进行预烧。预烧例如优选在空气中等的氧化性气氛中进行。预烧的温度优选为1100-1400℃的温度范围,更优选1100-1300℃,进一步优选1150-1300℃。预烧时间可以是1秒-10小时,优选为1秒-5小时。通过预烧获得的预烧体含有70%以上的上述主相(M相)。预烧体的一次粒径优选为10μm以下,更优选5μm以下,进一步优选2μm以下。
<粉碎工序>
粉碎工序中,将在预烧工序中形成颗粒状或块状的预烧体进行粉碎,再次制成粉末状。由此,后述的成型工序中的成型变得容易。在该粉碎工序中,如上所述,可以添加未在上述配合工序中配合的原料(原料的后添加)。粉碎工序例如可以通过2个阶段的工序进行:将预烧体进行粉碎成粗粉末(粗粉碎),然后将其进一步粉碎至微细(微粉碎)。
粗粉碎例如可使用振动磨等进行至平均粒径0.5-5.0μm。微粉碎中,将粗粉碎得到的粗粉碎材料进一步通过湿式磨碎机、球磨机、喷射磨等粉碎。微粉碎中,进行微粉碎至所得微粉碎材料的平均粒径优选0.08-2.0μm,更优选0.1-1.0μm,进一步优选0.1-0.5μm左右。微粉碎材料的比表面积(例如通过BET法求出)优选为4-12m2/g左右。适合的粉碎时间根据粉碎方法而不同,例如采用湿式磨碎机时,优选30分钟-20小时左右,通过球磨机的湿式粉碎中,优选为10-50小时左右。
在粉碎工序中添加原料的一部分时,例如,添加可在微粉碎时进行。本实施方案中,可以在在微粉碎时添加Si成分SiO2或Ca成分CaCO3,也可以在配合工序或粗粉碎工序中添加它们。
微粉碎工序中,采用湿式法时,除水之外,还可以使用甲苯、二甲苯等非水系溶剂作为分散介质。采用非水系溶剂,在后述的湿式成型时有获得高取向性的倾向。另一方面,使用水系溶剂时,从生产性的角度考虑为有利的。
另外,微粉碎工序中,为了提高烧结后所得烧结体的取向度,例如可以添加通式Cn(OH)nHn+2所示的多元醇。这里,多元醇优选在通式中的n为4-100,更优选4-30,进一步优选4-20,更进一步优选4-12。多元醇例如可举出山梨醇。另外也可以将2种以上的多元醇结合使用。并且,除多元醇之外还可以结合使用其它公知的分散剂。
添加多元醇时,其添加量相对于添加对象物(例如粗粉碎材料)优选为0.05-5.0质量%,更优选0.1-3.0质量%,进一步优选0.2-2.0质量%。尚需说明,在微粉碎工序中添加的多元醇可在后述的烧结工序中热分解除去。
然而,粉碎材料(优选微粉碎材料)的成型方法采用后述的CIM(Ceramic Injection Molding,陶瓷注射成型,即,为PIM(PowderInjection Molding,粉末注射成型)的一种)成型时,上述山梨醇等多元醇的添加会使得微粉碎浆料干燥时显著发生粉末的聚集,或者成为粉末在粘结剂树脂中分散变差等的主要因素,不优选。这种情况下可以不添加任何分散剂,或者用硅烷偶联剂等在同一分子内具有亲水性基团和疏水性(亲油性)基团的分散剂对粉末实施表面处理。该分散剂的添加量相对于添加对象物(例如粗粉碎材料)可以是0.3-3.0质量%。上述分散剂优选添加到微粉碎结束后的浆料中并混合,但并不限于该例子,也可以添加到干燥后的粉末中,或者在与粘结剂树脂的混炼工序中添加。
<成型·烧结工序>
成型·烧结工序中,将粉碎工序后得到的粉碎材料(优选微粉碎材料)成型,得到成型体,然后将该成型体烧结,得到烧结体。成型可以按照干式成型、湿式成型或CIM成型的任意方法进行。干式成型法中,例如将干燥的磁性粉末加压成型的同时施加磁场,形成成型体,然后对成型体进行烧结。湿式成型法中,例如将含有磁性粉末的浆料在施加磁场过程中加压成型,同时除去液体成分,形成成型体,然后对成型体进行烧结。
尚需说明,通常在干式成型法中,是将干燥的磁性粉末在模具内加压成型,因此具有成型工序所需时间短的优点,但是,成型时磁场导致的磁性粉末取向度难以提高,结果所得烧结磁铁的磁特性比湿式成型法得到的烧结磁铁差。另外,在湿式成型法中,成型时磁场使磁性粉末容易取向,烧结磁铁的磁特性良好,但是由于是一边抽取液体成分一边进行加压,因此存在成型费时的问题。
另外,CIM成型法是将干燥的磁性粉末与粘结剂树脂一起加热混炼,将形成的颗粒在施加了磁场的模具内注射成型,获得预备成型体,将该预备成型体进行脱粘结剂处理,然后进行烧结的方法。
上述实施方案的铁素体磁性材料的成型方法没有特别限定,但优选CIM成型、湿式成型,特别优选CIM成型。以下对CIM成型和湿式成型进行详细说明。
(CIM成型·烧结)
通过CIM成型法获得铁素体烧结磁铁时,在湿式粉碎后将含有磁性粉末的微粉碎浆料进行干燥,干燥温度优选80-150℃,进一步优选100-120℃。另外,干燥时间优选1-40小时,进一步优选5-25小时。干燥后的磁性粉末的一次粒子的平均粒径优选在0.08-2μm的范围内,进一步优选0.1-1μm的范围内。
将该干燥后的磁性粉末与粘结剂树脂、蜡类、润滑剂、增塑剂、升华性化合物等(以下将它们称为“有机成分”)一起混炼,通过制粒机等成型为颗粒。上述有机成分在成型体中优选含有35-60体积%,更优选40-55体积%。混炼例如可通过捏合机等进行。制粒机例如可使用双轴单轴挤出机。混炼以及颗粒成型可根据所使用的有机成分熔融温度,边加热边实施。
粘结剂树脂可使用热塑性树脂等高分子化合物,热塑性树脂例如可使用聚乙烯、聚丙烯、乙烯乙酸乙烯酯共聚物、无规聚丙烯、丙烯酸聚合物、聚苯乙烯、聚缩醛等。
蜡类可使用巴西棕榈蜡、褐煤蜡、蜜蜡等天然蜡,除此之外还可以使用石蜡、氨基甲酸酯化蜡、聚乙二醇等合成蜡。
润滑剂例如可使用脂肪酸酯等,增塑剂例如可使用邻苯二甲酸酯。
粘结剂树脂的添加量是相对于100质量%磁性粉末优选3-20质量%,蜡类的添加量优选3-20质量%,润滑剂的添加量优选0.1-5质量%。增塑剂的添加量是相对于100质量%粘结剂树脂优选0.1-5质量%。
本实施方案中,例如使用图4所示的磁场注射成型装置2,将上述颗粒10在模具8内注射成型。向模具8注射之前,先将模具8闭合,在内部形成型腔12,对模具8施加磁场。尚需说明,颗粒10是在挤出机6的内部加热熔融至例如160-230℃,通过螺杆向模具8的型腔12内注射。模具8的温度为20-80℃。对模具8施加的磁场可以是398-1592kA/m(5-20kOe)左右。
接着,将通过CIM成型得到的预备成型体在大气中或氮气中、在100-600℃的温度下热处理而进行脱粘结剂处理,获得成型体。脱粘结剂处理不充分或者脱粘结剂时的升温速度急剧,则由于上述有机成分的急剧挥发或分解气体的产生,在成型体或烧结体上产生破裂或裂隙。因此,可根据要进行脱粘结剂处理的有机成分,将挥发或分解的温度区域的升温速度适当调节为例如0.01-1℃/分钟左右的缓慢的升温速度,进行脱粘结剂处理。相反,如果脱粘结剂处理过度,则成型体的保型力不足,产生缺陷,因此必须进行热处理温度或温度分布的控制。另外,使用多种有机成分时,可以将脱粘结剂处理分多次实施。
接着,在烧结工序中,将脱粘结剂处理后的成型体例如在大气中、优选在1100-1250℃、更优选1160-1230℃的温度下烧结0.2-3小时左右,获得本发明的铁素体烧结磁铁。温度过于低温或温度保持时间过短,则由于无法获得充分的烧结体密度或者所添加的元素反应不充分等原因,无法获得所需的磁特性。另外,烧结温度过于高温或温度保持时间过长,则由于晶体粒子异常生长或者产生M型铁素体以外的异相等原因,同样无法获得所需的磁特性。尚需说明,烧结工序可以与上述脱粘结工序连续实施,也可以在一旦进行脱粘结剂处理后冷却至室温,然后实施烧结。
(湿式成型·烧结)
通过湿式成型法获得铁素体烧结磁铁时,优选例如,以湿式进行上述的微粉碎工序,得到浆料,然后将该浆料浓缩至规定浓度,得到湿式成型用浆料,使用该浆料进行成型。浆料的浓缩可通过离心分离或压滤等进行。对于湿式成型用浆料,优选在其总量中微粉碎材料占30-80质量%左右。在浆料中,优选水作为使微粉碎材料分散的分散介质。这种情况下,浆料中可以添加葡糖酸、葡糖酸盐、山梨醇等表面活性剂。也可以使用非水系溶剂作为分散介质。非水系溶剂可以使用甲苯或二甲苯等有机溶剂。这种情况下,优选添加油酸等表面活性剂。尚需说明,湿式成型用浆料可通过在微粉碎后的干燥状态的微粉碎材料中添加分散介质等来制备。
湿式成型中,接着对该湿式成型用浆料进行磁场中成型。这种情况下,成型压力优选9.8-49MPa(0.1-0.5吨/cm2)左右,施加磁场可以是398-1592kA/m左右。另外,成型时加压方向和磁场施加方向可以是同一方向也可以是正交方向。
通过湿式成型获得的成型体的烧结可在大气中等氧化性气氛中进行。烧结温度优选1050-1270℃,更优选1080-1240℃。而烧结时间(保持烧结温度的时间)优选为0.5-3小时左右。
尚需说明,通过上述湿式成型获得成型体时,若在不使该成型体充分干燥的状态下进行烧结,导致急剧加热,则剧烈发生分散介质等的挥发,可能在成型体中产生裂隙。因此,从避免上述问题的角度考虑,优选在达到上述烧结温度之前,例如以0.5℃/分钟左右的缓慢的升温速度由室温加热至100℃左右,使成型体充分干燥,由此可以抑制裂隙的发生。并且,添加表面活性剂(分散剂)等时,优选例如在100-500℃左右的温度范围内、以2.5℃/分钟左右的升温速度进行加热,由此可以充分除去这些物质(脱脂处理)。尚需说明,这些处理可以在烧结工序的最初进行,也可以在烧结工序之前另行进行。
以上,对于铁素体烧结磁铁的合适制造方法进行了说明,但只要至少使用本发明的铁素体磁性材料即可,制造方法并不限于上述,条件等可以适当变更。
另外,制造不是铁素体烧结磁铁而是粘结磁铁的磁铁时,例如可在进行至上述粉碎工序后,将所得粉碎物与粘结剂混合,将其在磁场中成型,由此可以得到含有本发明的铁素体磁性材料的粉末的粘结磁铁。或者将在粉碎工序中得到的浆料进行干燥,将所得铁素体磁性材料粉末在例如1000-1200℃左右的不进行烧结的温度下进行热处理,然后通过磨碎机破碎,将所得磁性粉末与粘结剂混合,可以得到粘结磁铁。
由本发明得到的磁铁只要由本发明的铁素体磁性材料构成即可,形态没有限定。例如铁素体磁铁可以是具有各向异性的弧段状、平板状、圆柱状等各种形状。尚需说明,上述弧段状是将平板状材料在一个方向上弯曲为圆弧状所成的形状。根据本发明的铁素体磁性材料,与磁铁的形状无关,均可保持高Br和HcJ、同时获得高的Hk/HcJ,特别是弧段状的磁铁,也可保持高Br和HcJ、同时获得高的Hk/HcJ。
本实施方案中的铁素体磁铁例如可作为燃油泵用、电动车窗用、ABS(防抱死制动系统)用、风扇用、雨刷器用、动力转向装置用、主动悬挂装置用、起动装置用、门锁用、电动后视镜用等的汽车用马达部件使用。
还可作为FDD心轴用、VTR主动轮用、VTR旋转头用、VTR卷轴用、VTR装载用、VTR摄像主动轮用、VTR摄像旋转头用、VTR摄像变焦用、VTR摄像聚焦用、收录机等主动轮用、CD/DVD/MD心轴用、CD/DVD/MD装载用、CD/DVD光学拾波器用等的OA/AV机器用马达部件使用。
进一步可作为空调压缩机用、冷库压缩机用、电动工具驱动用、鼓风干燥机用、电动剃须刀驱动用、电动牙刷用等的家电机器用马达的部件使用。还可进一步作为机器人轴、关节驱动用、机器人主驱动用、工作仪器台传动用、工作仪器带传动用等FA机器用马达的部件使用。其它的用途可举出摩托车用发电器、扬声器·耳机用磁铁、磁控管、MRI用磁场发生装置、CD-ROM用夹持器(Clamper)、配电器用传感器、ABS用传感器、燃料·油水平传感器、磁锁存器(magnet latch)、隔离器(isolator)等部件。或者可作为在通过蒸镀法或溅射法等形成磁记录介质的磁性层时的靶(颗粒)使用。
实施例
以下,通过实施例更进一步详细说明本发明,但本发明并不受这些实施例的限定。
实施例1-6
<配合工序>
首先,准备构成铁素体烧结磁铁的金属元素的化合物的粉末作为起始原料。起始原料为准备氧化铁(Fe2O3,作为杂质含有Mn、Cr、Al、Si、Cl)、氢氧化镧(La(OH)3)、碳酸钙(CaCO3)、碳酸锶(SrCO3)、碳酸钡(BaCO3)、氧化钴(Co3O4),称量使其成为表1-6所示各试样的组成。另外,作为Si成分原料,称量氧化硅(SiO2,含水率约20%左右,以下也使用同一原料),使其相对于起始原料的总量为表1-6所示各试样的组成。
尚需说明,分别改变实施例1(表1)中的Sr的比率(x)与Ca的比率(1-w-x-y)、实施例2(表2)中的La的比率(w)和La/Co的比率(w/m)、实施例3(表3)中的Ba的比率(y)、实施例4(表4)中的Co/Fe的比率(m/z)、实施例5(表5)中的Fe的比率(z)、实施例6(表6)中的SiO2的含量,制作试样。
<预烧工序>
将上述起始原料和SiO2、各粉末通过湿式磨碎机混合,粉碎,得到浆状原料组合物。将该原料组合物干燥后,在大气中于1225℃下保持2小时,进行预烧处理,得到预烧体。
<粉碎工序>
将所得预烧体用小型批量(ロツト)振动磨粗粉碎,得到粗粉碎材料。对所得粗粉碎材料分别适当添加氧化铁(Fe2O3,作为杂质含有Mn、Cr、Al、Si、Cl)、碳酸钙(CaCO3)、碳酸锶(SrCO3)、氧化钴(Co3O4)以及作为副成分的氧化硅(SiO2),同时添加0.45wt%山梨醇,使得构成烧结后的铁素体烧结磁铁的金属元素比率为表1-6所述各试样所示的值。接着,用湿式球磨机进行微粉碎,使得按照BET法求出的比表面积(SSA)为8.0-9.0m2/g,得到浆料。将所得浆料进行干燥,分粒,得到铁素体材料粉末。
<成型·烧结工序>
成型通过CIM成型进行。首先,准备上述实施工序中所得的铁素体材料粉末、PP(聚丙烯,作为粘结剂树脂使用)、石蜡、丙烯酸树脂和DOP(邻苯二甲酸二辛基酯,作为增塑剂添加),将其进行称量,使铁素体材料粉末=87质量%、PP=5.1质量%、石蜡=5.1质量%、丙烯酸树脂=1质量%、DOP=2质量%。接着使用加压加热捏合机,在165℃下将它们混炼2.5小时,用制粒机将混炼物(复合物)成型为颗粒状,得到图4所示的颗粒10.
接着,使用图4所示的磁场注射成型装置2,将颗粒10在模具8内注射成型。在向模具8注射之前,将模具8闭合,在内部形成型腔12,对模具8施加磁场。尚需说明,颗粒10在挤出机6的内部加热熔融,通过螺杆注射到模具8的型腔12内。注射温度为185℃,模具温度为40℃,注射时的施加磁场为1273kA/m。由磁场注射成型工序得到的预备成型体为圆板状,直径30mm,厚度3mm。
在加湿的大气气氛中、在最高到达温度230℃下对预备成型体实施合计50小时的热处理,进行脱蜡处理。将该脱蜡处理的成型体在大气中缓慢升温至150-500℃,进行脱粘结剂处理,接着在大气中在1190-1230℃下保持1小时,进行烧结,得到为烧结体的铁素体烧结磁铁。
实施例7
实施例7中,在成型工序中将成型体中的有机成分的体积百分率改变为表7所示的值,除此之外与实施例1-6同样地进行,得到铁素体烧结体。尚需说明,上述有机成分是PP(聚丙烯)、石蜡、丙烯酸树脂和DOP(邻苯二甲酸二辛基酯)的合计,即使成型体中有机成分比例变化,也固定PP、石蜡、丙烯酸树脂、DOP的混合比率,成为如实施例1所示的比率。
实施例7中,通过改变成型体中有机成分的体积比例,使烧结磁铁的晶体取向度、晶体粒径、长宽比变化。
实施例8
实施例8中,在粉碎工序中不添加山梨醇,并对铁素体材料粉末(填料)进行硅烷偶联剂处理,除此之外与实施例1-6同样地制作铁素体烧结磁铁,并进行评价。具体来说,实施例8中,在粗粉碎材料中不添加山梨醇地实施微粉碎,在微粉碎结束后,相对于粗粉碎材料,在微粉碎浆料中添加1wt%硅烷偶联剂(信越シリコ一ン(株)制造,KBM-503、KBM-1003),进一步用湿式球磨机混合0.5小时,进行分散处理,除此之外与实施例1-6同样地进行,得到铁素体烧结磁铁。
实施例9
实施例9是将CIM成型改为湿式成型,除此之外与实施例1-6同样地进行,得到铁素体烧结磁铁,并进行评价。即,实施例9中,如下进行成型·烧结工序。
首先,以甲苯作为分散介质实施微粉碎,得到微粉碎浆料。该微粉碎时,相对于粗粉碎材料添加1.3wt%油酸。调节溶剂量,使所得浆料的固体成分浓度为74-76质量%,使用湿式磁场成型机,施加磁场为1.2T,将该浆料在磁场中成型,制作直径30mm、高15mm的圆柱状成型体。接着,将所得成型体在大气中在室温下充分干燥,然后在大气中在1200-1230℃下保持1小时进行烧结,得到为烧结体的铁素体烧结磁铁。
对于实施例1-9的各铁素体烧结磁铁进行荧光X射线定量分析,可确认各铁素体烧结磁铁分别为表1-9所示组成。
<磁特性(Br、HcJ、Hk)的测定>
首先,对于实施例1-9的各试样,通过阿基米德法进行密度测定。
接着,对实施例1-9的各铁素体烧结磁铁的上下面进行加工,然后在25℃的大气气氛中使用最大施加磁场为1989kA/m的B-H磁特性记录仪(B-H tracer)测定磁特性(剩余磁通密度Br、矫顽力HcJ、矩形比Hk/HcJ)。结果如表1-9所示。这里,Hk是在磁滞回线的第2象限中磁通密度为剩余磁通密度的90%时的外部磁场强度。
<晶体取向度>
对于实施例1的试样编号1-4、实施例5的试样编号5-5、实施例6-9的各试样,将圆板状的铁素体烧结磁铁的一个面研磨平滑,对该平滑研磨面进行XRD(X射线衍射)测定(X射线源:CuKα),识别来自铁素体烧结磁铁的衍射峰。由所识别的衍射峰的面指数和峰强度求出烧结磁铁的晶体取向度Or(f)。尚需说明,表1的试样编号1-4、表5的试样编号5-4为同一试样,因此表5试样编号5-4栏中也同样示出晶体取向度。
<晶体粒径、长宽比>
对于各铁素体烧结磁铁,如下所述求出晶体粒径和长宽比。
首先,切取与铁素体烧结磁铁的c轴(易磁化轴)方向平行的剖面,在该剖面进行镜面研磨,用氢氟酸(浓度36%)进行蚀刻处理。接着,用扫描式电子显微镜(SEM)观察蚀刻处理面,得到晶体粒子的剖面图像。图3(a)表示试样编号1-4(或3-3、4-4、5-4、7-8)的SEM剖面图像,图3(b)表示试样编号7-1的SEM剖面图像。
对于由SEM观察得到的晶体粒子剖面图像进行图像分析处理,如图2所示,对各晶体粒子测定通过晶体粒子剖面重心J的粒径的最大值1(μm)和最小值s(μm)。通过上述方法求出500个晶体粒子的粒径最大值1和最小值s,分别计算它们的最大值1的算术平均值(平均最大粒径L)和最小值s的算术平均值(平均最小粒径S),由平均最大粒径L和平均最小粒径s求出长宽比L/S。求出的平均最大粒径L与长宽比L/S表示在表1-9中。尚需说明,表1的试样编号1-4、表5的试样编号5-4是同一试样,因此,在表5的试样编号5-4栏中也同样示出平均最大粒径L和长宽比L/S。
实施例1-9的各试样的组成、磁特性、晶体取向度、晶体粒径和长宽比汇总表示于表1-9中。
[表1]
[表2]
[表3]
[表4]
[表5]
[表6]
[表7]
[表8]
[表9]
由表1表明,Sr的比率(x)超过0.0003但低于0.373、Ca比率(1-w-x-y)超过0.229但低于0.601,则可良好保持Br和HcJ,可得到高的Hk/HcJ。由表1进一步表明,Sr的比率(x)为0.05-0.25、Ca比率(1-w-x-y)为0.354-0.551,则可良好保持Br和HcJ,同时可得到更高的Hk/HcJ。
由表2表明,La的比率(w)超过0.180但低于0.550、La/Co(w/m)超过0.72但低于2.20,则可良好保持Br和HcJ,同时可得到高的Hk/HcJ。由表2表明,进一步使La的比率(w)为0.3以上但低于0.5、La/Co(w/m)为1.2-1.9,则可更加良好保持Br和HcJ,同时可得到更高的Hk/HcJ。
由表3表明,Ba的比率(y)超过0.0001但低于0.0150,则可良好保持Br和HcJ,同时可得到高的Hk/HcJ。还可确认,Sr的比率(x)比Ba的比率(y)小的样品3-11特别在Br和Hk/HcJ方面不充分。由表3表明,进一步使Ba的比率(y)为0.0004-0.01,则可更加良好保持Br和HcJ,同时可得到更高的Hk/HcJ。
由表4表明,Co/Fe(m/z)超过0.012但低于0.065,则可良好保持Br和HcJ,同时可得到高的Hk/HcJ。由表4表明,进一步使Co/Fe(m/z)为0.020-0.035,则可进一步良好保持Br和HcJ,同时可得到更高的Hk/HcJ。
由表5表明,Fe的比率(z)超过8.62但低于9.97,则可良好保持Br和HcJ,同时可得到高的Hk/HcJ。由表5表明,进一步使Fe的比率(z)为8.8-9.6,则可进一步良好保持Br和HcJ,同时可得到更高的Hk/HcJ。
如表6所示,将上述铁素体磁性材料中的上述Si成分换算为SiO2的比率y1质量%在Y轴表示、将上述z和m的合计量x1在X轴表示时,x1与y1的关系在由具有上述X轴和Y轴的X-Y坐标中的4个点a(8.9,1.2)、b(8.3,0.95)、c(10.0,0.35)和d(10.6,0.6)所包围的范围内,则可良好保持Br和HcJ,同时可得到高的Hk/HcJ。
由表7表明,在上述铁素体磁性材料中,通过X射线衍射测定求出的晶体取向度Or(f)=∑(001)/∑(hkl)超过0.78,则可良好保持Br和HcJ,同时可获得高的Hk/HcJ。
另外由表7可确认,在上述铁素体磁性材料中,平均最大粒径L低于1.47或L/S低于2.46,则可获得高的HcJ。
由表8表明,使用经硅烷偶联剂处理的铁素体磁性粉末,也可良好保持Br和HcJ,同时可获得高的Hk/HcJ。
由表9表明,在通过湿式成型得到的试样中,也可良好保持Br和HcJ,同时可获得高的Hk/HcJ。
符号说明
2 磁场注射成型装置
8 模具
10 颗粒
12 型腔
20 晶体粒子
Claims (7)
1.铁素体磁性材料,该铁素体磁性材料具有由有六方晶结构的铁素体相构成的主相,其特征在于,构成上述铁素体磁性材料的金属元素的组成由下述式(1)表示:
Ca1-w-x-yRwSrxBayFezMm ・・・(1)
条件是,式(1)中,R为选自包含Y的稀土类元素和Bi中的至少一种元素并至少含有La,M为选自Co、Mn、Mg、Ni、Cu和Zn中的至少一种元素并至少含有Co,
上述式(1)中,w、x、y、z和m满足下述式(2)、(3)、(4)、(5)、(6)、(7)和(8):
0.25<w<0.5 ・・・(2)
0.01<x<0.35 ・・・(3)
0.0001<y<0.013 ・・・(4)
y<x ・・・(5)
8.7<z<9.9 ・・・(6)
1.0<w/m<2.1 ・・・(7)
0.017<m/z<0.055 ・・・(8),
至少含有Si成分作为副成分,
将上述铁素体磁性材料中的上述Si成分换算为SiO2的含量y1质量%在Y轴表示,并将上述z与m的合计量x1在X轴表示时,x1与y1的关系在具有上述X轴和Y轴的X-Y坐标中的4个点a (8.9,1.2)、b (8.3,0.95)、c (10.0,0.35)和d (10.6,0.6)所包围的范围内。
2.铁素体磁铁,该铁素体磁铁含有权利要求1所述的铁素体磁性材料。
3.权利要求2所述的铁素体磁铁,其特征在于,上述铁素体磁铁中,通过X射线衍射测定求出的晶体取向度Or(f)=ΣI(001)/ΣI(hkl)为0.9以上,其中,
(00L)是表示晶体结构中c面的总称,
ΣI(00L)表示归属于(00L)面的所有峰强度的合计,
(hkL)表示所检测出的所有的衍射峰,且ΣI(hkL)是所有这些峰强度的合计。
4.权利要求2或3所述的铁素体磁铁,其中,在将构成上述铁素体磁铁的晶体粒子沿与c轴方向平行的面切断所得的剖面中,分别求出通过上述各晶体粒子剖面重心的粒径的最大值和最小值,当500个以上的晶体粒子中、上述粒径的最大值和最小值的平均分别设为L (μm)、S (μm)时,上述L和S满足下述式(9)和(10):
L≦1.4 ・・・(9)
L/S≦2.4 ・・・(10) 。
5.铁素体烧结磁铁,该铁素体烧结磁铁含有权利要求1所述的铁素体磁性材料。
6.权利要求5所述的铁素体烧结磁铁,其特征在于,在上述铁素体烧结磁铁中,通过X射线衍射测定求出的晶体取向度Or(f)=ΣI(001)/ΣI(hkl)为0.9以上,其中,
(00L)是表示晶体结构中c面的总称,
ΣI(00L)表示归属于(00L)面的所有峰强度的合计,
(hkL)表示所检测出的所有的衍射峰,且ΣI(hkL)是所有这些峰强度的合计。
7.权利要求5或6所述的铁素体烧结磁铁,其中,在将构成上述铁素体烧结磁铁的晶体粒子沿与c轴方向平行的面切断所得的剖面中,分别求出通过上述各晶体粒子剖面重心的粒径的最大值和最小值,当500个以上的晶体粒子中、上述粒径的最大值和最小值的平均分别设为L (μm)、S (μm)时,上述L和S满足下述式(9)和(10):
L≦1.4 ・・・(9)
L/S≦2.4 ・・・(10) 。
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