CN102834207A - 磁性粉末冶金材料 - Google Patents
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Abstract
本发明涉及用粉末冶金方法制作的导电性的压实的金属部件。本发明的铁基粉末涂覆有磁性或预磁性材料。
Description
相关申请的交叉引用
本申请要求2010年4月1日提交的美国临时申请No.61/319,987的权益,该临时申请以其全文结合于此。
技术领域
本发明涉及涂覆有磁性或预磁性涂层的冶金粉末组合物,以及使用所述粉末制作的压实的金属部件。
背景技术
交变电流(AC)指的是将电力传送到大多数家庭及工商企业时所采用的正弦波。靠AC运转的装置几乎无一例外地含有由“层压钢条(laminated steel strip)”制成的芯,所述芯用于传送将电能转换为机械能所必需的磁通量。通过从薄的、即通常为约0.045英寸到约0.010英寸(约1.1mm到约0.25mm)厚的金属片冲压成所需形状来制备这些“层压件(laminate)”,所述金属通常为用或没用合金元素例如硅制造的锻钢。为避免沿着钢条表面产生涡电流,所述层压件必须是薄的。涡电流是当导体处于变化的磁场中的时候所产生的一种电学现象,在导体上产生了电子的循环流,即电流。电流的这些循环涡流产生了与原磁场的变化相反的感应磁场,在导体和磁体之间引起排斥力或拖曳力。涡电流抵抗磁通量并产生热量,使得装置的效率降低。涡电流的强度与金属的厚度成正比。可以根据下式计算由涡电流引起的损耗:
涡电流损耗=K*(freq^2*Ind^2*厚度^2)/电阻率
其中,K=常数;Freq=交变电流的频率;Ind=感应的作用级别(operating level of induction);以及厚度=片或粉末冶金部件的厚度。
对于大多数装置而言,单个层压条不足以传送所需量的磁通量。所以,通常将多个层压条相互叠加产生具有所需尺寸的部件。当层压条的叠加产生更大、“更厚”的部件时,对形成涡电流的影响被叠加条之间存在的磁阻氧化物降到最低,所述氧化物在层压件的制备过程中自然形成于层压件的表面上。层压件之间的磁阻和电阻氧化物防止了由所产生的叠加件的厚度形成的有害的涡电流。
尽管很受欢迎且已使用超过100年,但层压钢条还是具有缺点。例如,由于所述条是从片材冲压而成的,无法将金属片全部冲压成条就不可避免的带来材料的损失。另外,由于所述条是通过辊压形成的,因此,磁通量沿辊压的方向传播。所以,不能用层压钢条来制备在大于一个方向上需要磁通量的装置。
粉末冶金(PM)是一种生产技术,其中,将金属粉末在非常高的压力下在模子或模具中压缩,以产生压实的部件。然后可以将压实的部件退火和/或烧结来增加最终金属部件的强度。用粉末冶金(PM)方法制备的部件已被认为是层压钢条的替代物;粉末冶金没有钢条制备过程中存在的材料损失问题——在制备压实的部件的过程中,没有浪费任何粉末。但PM不适用于形成钢条,因为用目前的PM方法不能获得所需要的薄度。
尽管PM通常不利于形成薄钢条,但它对制备其它种类的金属部件却很有效。PM提供了独特的、极好的塑形能力,并可以制备效率优化的三维形体。而且,如果单个的粒子之间互相绝缘,在压实并烧结的部件中,涡电流可被最小化。以前使粉末粒子绝缘的尝试依赖于将聚合物或其它材料沉积到铁粉表面上。出于这个目的,特别优选的是磷酸铁。但是,这些材料是绝缘体,而且他们的存在阻碍磁流穿过金属部件。因此,需要更多的电能来弥补减少的磁流,这是不希望的。而且,使用这些材料的涂层是薄的,并在升高的温度下分解,导致不能被“应力缓解(stress relieved)”的粉末,即,在压实期间引起的应变降低。
另外,尽管磷酸铁和聚合物有助于维持在压实的部件中的金属粉末的离散粒子特性,但它们使温度稳定性降低。例如,磷酸铁系统仅能被加热到约425°C。大多数基于聚合物的系统仅能被加热到约250°C。因此,压实的部件的磁响应不能通过通常在高于650°C的温度下进行的退火或烧结来提高。
铁素体是主要组分为氧化铁(III)(Fe2O3)的陶瓷,但它们常常包含氧化镍、氧化锌和/或氧化镁。很多类型的铁素体是具有磁性的,并被用于制造永磁体、变压器的铁素体芯等。这些铁素体,也称作软铁素体,具有低矫顽力,这指的是这些材料的磁化可以在不消耗很多能量的条件下轻易地颠倒方向,同时铁素体的高电阻率防止了涡电流。
美国专利号6,689,183描述了铁粉和细碾磨的铁素体粒子的物理混合物的PM应用。该混合物是不均匀的,含有铁粉和铁素体的离散粒子。将这样的混合物压实并烧结或退火并不会产生功能性梯度结构,意思是无法获得在最终部件中的离散粒子特性,而这是使用具有表面涂层的铁粉粒子时所能获得的。所以,从用这种不均匀的混合物制成的压实的部件中通过的磁流并不均一。而且,由于在该系统中无法避免粒子和粒子间的接触,所以涡电流损耗增加。
申请人已给出使用涂覆有铁素体的铁粉粒子的考虑因素。这样可以在协助保持粉末的离散粒子特性的同时,获得导磁性铁素体的均匀分布,以减少涡电流效应。但是与铁粉相比,铁素体和大多数氧化物一样具有较差的可压缩性。因此,使用涂覆有铁素体的粉末会导致粉末的可压缩性降低,产生密度较小且较弱的压实的部件。而且,铁素体易碎,在压实期间可能破裂,导致单个铁粒子上的铁素体涂层的潜在中断。
所以,所需要的是可以用于制备压实的金属部件的粉末冶金材料和方法,在所述压实的金属部件中,铁粉的离散颗粒特性得到保持并借助环绕的磁性材料相,在压实并烧结的部件中彼此分离。优选地,为增加压实的部件的磁化率(magnetic capacity),这些材料允许压实的部件在至少650°C的温度下退火。压实的部件还必须具有高效电装置所必需的高磁导率以及高磁感应系数。
发明内容
本发明涉及包含铁基冶金粉末的冶金粉末组合物,其中所述铁基粉末的粒子涂覆有至少一种磁性或预磁性材料。本发明还描述了制备所述粉末的方法以及使用所述粉末形成压实的磁性部件的方法。
附图说明
图1描绘了空隙中插入了一片铁素体(例如锰锌铁素体)的磁线圈(toroid)。
说明性实施方式的详细描述
本发明涉及涂覆有至少一种磁性或预磁性材料的冶金粉末。优选地,这些组合物包含铁基冶金粉末,其中铁基粉末的粒子涂覆有至少一种磁性或预磁性材料。所述粒子可以基本上、部分或全部涂覆有至少一种磁性或预磁性材料。这些冶金粉末在压实并退火时产生在粉末冶金领域中以前未获得过的具有磁性的压实的部件。
本发明的铁基冶金粉末通常含有这样的铁粉,即所述铁粉是占铁基冶金粉末的至少90重量%的铁。这样的铁粉,即铁基冶金粉末的至少95重量%的铁和99重量%的铁,也在本发明的范围内。
用于本发明的基本上纯的铁粉是含有不超过约1.0重量%、优选不超过约0.5重量%的一般杂质的铁粉。这种具有高度可压缩性的冶金级铁粉的实例为可从Hoeganaes Corporation,Riverton,New Jersey购买的纯铁粉的ANCORSTEEL 1000系列,例如1000、1000B和1000C。例如,ANCORSTEEL 1000铁粉的筛分谱通常为,约22重量%的粒子小于325号筛(美国系列),约10重量%的粒子大于100号筛,其余粒子在这两种尺寸之间(痕量粒子大于60号筛)。ANCORSTEEL 1000粉末的表观密度为约2.85-3.00g/cm3,通常为2.94g/cm3。用于本发明的其它铁粉为典型的海绵铁粉,例如Hoeganaes的ANCOR MH-100粉末以及ANCORSTEEL AMH,后者为一种低表观密度的雾化铁粉。
铁粒子的平均粒径可以小至约5微米,或高达约850-1000微米,但通常所述粒子的平均直径在约10-500微米、或约5微米到约400微米、或者约5微米到约200微米的范围内。平均粒径可以通过本领域已知的激光衍射技术来进行测量。
在本发明的一些实施方式中,铁粉粒子涂覆有磁性材料。优选地,所述磁性材料为金属氧化物。在本文中使用时,“金属氧化物”是过渡金属的氧化物。优选的金属氧化物包括氧化镍、氧化锰、氧化铁、及其组合。
在其他实施方式中,铁粉粒子涂覆有铁素体材料。软磁性铁素体是由三氧化二铁和一种或多种其他金属例如镁、铝、锰、铜、锌、镍、钴和铁组成的陶瓷样氧化物。取决于组成,铁素体通常为锰锌铁素体和镍锌铁素体这两类中的一种。
另外,在其他实施方式中,铁粉粒子涂覆有预磁性材料。在本文中使用时,“预磁性材料”是没有磁性、但在热处理后变成具有磁性的材料。预磁性材料的优选实例包括预铁素体材料。在本文中使用时,“预铁素体材料”是在热处理、例如退火或烧结之后转变成铁素体材料的非铁素体材料。预铁素体材料的实例包括金属碳酸盐和金属卤化物。这些材料在用于涂覆铁粉粒子时,会在受热后、优选退火后转化成铁素体。
“金属碳酸盐”是过渡金属的碳酸盐。优选的金属碳酸盐包括碳酸铁、碳酸锌、碳酸锰、碳酸镍或其混合物。“金属卤化物”是过渡金属的卤化物。优选地,卤化物为氟化物、氯化物、溴化物或碘化物。优选的金属卤化物包括氯化锌和溴化锌。优选地,前述混合物包含按总重量计约1%到约2%的金属碳酸盐和/或金属卤化物。
在优选实施方式中,所述磁性或预磁性涂层的厚度在约5微米和约40微米之间。
用于本发明的磁性粉末组合物可以通过将铁基粉末与磁性材料的溶液混合来制备,所述磁性材料例如为铁素体或金属氧化物,例如氧化镍、氧化锰、氧化铁、或其组合。在一些实施方式中,将磁性材料溶于或悬浮于水或溶剂例如醇溶剂如乙醇、甲醇、丙醇或其混合物中。其它溶剂包括丙酮、醚、乙酸乙酯、甲基乙基酮、二氯甲烷、己烷、二甲苯、甲苯等。还设想了含水或不含水的前述任何溶剂的混合物。优选地,所述溶液是用磁性材料饱和的。在将铁基粉末与磁性材料的溶液搅拌之后,从溶液中去除固体粉末并去除残留的溶剂。例如,通过加热去除溶剂后得到了冶金粉末组合物,其中铁基粉末的单个粒子涂覆有磁性材料。
用于本发明的预磁性冶金粉末组合物例如预铁素体组合物的制备可以通过将铁基粉末与预铁素体材料例如至少一种金属碳酸盐和/或金属卤化物的溶液混合。在一些实施方式中,将预磁性材料溶于或悬浮于水或溶剂例如醇溶剂如乙醇、甲醇、丙醇或其混合物中。其它溶剂包括丙酮、醚、乙酸乙酯、甲基乙基酮、二氯甲烷、己烷、二甲苯、甲苯等。优选地,所述溶液是用预磁性材料饱和的。在将铁基粉末与预磁性材料的溶液搅拌之后,从溶液中去除固体粉末并去除残留的溶剂。例如,通过加热去除溶剂后得到了预磁性冶金粉末组合物,其中铁基粉末的单个粒子涂覆有预磁性材料。
在将磁性或预磁性冶金粉末组合物干燥后,可以按照传统的冶金技术将所述组合物在模具中压实形成压实的金属部件。可以将所述模具,因而也即所述部件塑造成用于例如电动机组件或变压器的芯的形状。压实的金属部件的密度可以通过使用加热过的模具和/或通过加热预铁素体冶金粉末来进一步最大化。压实的金属部件的制备可以通过在至少约5tsi的压力下将本发明的冶金粉末组合物在模具中压缩来形成绿色部件。压实压力通常为约5-100吨/平方英寸(69-1379MPa),优选约20-100tsi(276-1379MPa),以及更优选约25-70tsi(345-966MPa)。
预润滑模具壁和/或在冶金粉末中混入润滑剂,因为润滑了所述粉末的粒子,从而有利于压实的部件的脱模,同时也有助于再次填料的过程。适用于PM的润滑剂是本领域技术人员公知的,并包括例如硬脂酸盐。
随后将压实的绿色部件按照传统冶金技术退火。优选地,炉温高于1110°F。通常炉温为约1100°F到约2370°F。
炉内气氛通常包括“保护性气氛”。在本文中使用时,“保护性气氛”指的是主要由惰性气体组成的气氛。优选的气氛主要含有氮气及一些氧气。通常,所述气氛含有氮气及至少0.1%的氧气。优选地,所述气氛含有约0.1%到约5%的氧气。
在退火后,预磁性材料例如预铁素体材料如金属碳酸盐和/或金属卤化物将转变为磁性材料,例如铁素体。通过对烧结的部件的磁性检测来确认磁性材料的形成。优选地,本发明的退火/烧结的部件的磁导率为约1000μ;但是其他磁导率也在本发明的范围之内。“磁导率”定义为磁化曲线的瞬时斜率。最大磁导率是所获得的磁导率的最大数值。
本发明的退火部件还具有小于约3奥斯特、优选约2奥斯特到约3奥斯特(Oe)(约159安匝/米[At/m]到约239安匝/米[At/m])的矫顽力。“矫顽力”是施加到处于对称的循环磁化方式中的磁性材料上使磁感应消失所必需的磁场。
本领域技术人员会意识到,可以对本发明的优选实施方式做出多种改变和修改,而且可以在不脱离本发明精神的情况下做出这样的改变和修改。以下实施例进一步描述了本发明,而不是用于限制本发明。
实施例
以下实验演示了本发明概念的证据。
将Ancorsteel 1000B(0.15%Mn,0.02%Ni,0.05%Cr,Bal铁)辊压成条。该条经测量为0.05英寸(1.25mm)厚,约8英寸(200mm)宽。在辊压后,所述条基本上无孔(100%致密)。将所述条加工成磁线圈,然后在1500°F(815°C)下退火1小时以消除冷作业的有害影响,随后加工成在磁路上引入不同宽度的空隙。对所述条进行磁性检测来评估它的磁性。检测结果列于表1。
获得一片锰锌铁素体,并将其准确切成0.048英寸(1.25mm)厚,放入空隙中,然后在所得条上再次进行磁性检测。检测结果列于表1。磁性铁素体楔子的引入导致磁导率提高100%,以及感应的显著改进。磁导率被提高到大于~1300的数值(数值1000代表磁性装置中所要求的关键设计参数)。
用于空隙磁线圈中的铁的体积是总体积的~98.8%,铁素体的体积为1.2%。考虑到各材料的密度并假设铁的比密度为7.85g/cm3,而锰铁素体的密度为5.3g/cm3,那么铁的重量百分比为99.2%而铁素体的重量百分比为~0.8%。
表1:有或没有铁素体的空隙的效应
表1所示结果证实了在磁性材料的空隙中掺入高阻铁素体的可能性。表1所示带空隙锻钢的数据是AC粉末冶金材料的当前技术状态的最好代表。
Claims (31)
1.含有铁基冶金粉末的冶金粉末组合物,其中铁基粉末的粒子涂覆有至少一种磁性或预磁性材料。
2.权利要求1的冶金粉末组合物,其中铁基粉末的粒子涂覆有至少一种磁性材料。
3.权利要求2的冶金粉末组合物,其中磁性材料是金属氧化物。
4.权利要求3的冶金粉末组合物,其中金属氧化物为氧化镍、氧化锰、氧化铁或其组合。
5.权利要求1的冶金粉末组合物,其中铁基粉末的粒子涂覆有至少一种预磁性材料。
6.权利要求5的冶金粉末组合物,其中预磁性材料是预铁素体材料。
7.权利要求6的冶金粉末组合物,其中预铁素体材料包含至少一种金属碳酸盐和/或金属卤化物。
8.权利要求7的冶金粉末组合物,其中金属碳酸盐为碳酸铁、碳酸锌、碳酸锰、碳酸镍或其组合。
9.权利要求7的冶金粉末组合物,其中金属卤化物为氯化锌或溴化锌。
10.权利要求7的冶金粉末组合物,其含有占预铁素体材料的约1重量%和2重量%之间的金属碳酸盐。
11.权利要求1的冶金粉末组合物,其中铁基冶金粉末为占铁基冶金粉末的至少约90重量%的铁。
12.权利要求1的冶金粉末组合物,其中当用激光衍射测量时,铁基冶金粉末粒子的平均直径在约5微米和约1000微米之间。
13.权利要求1的冶金粉末组合物,其中铁基冶金粉末粒子的直径在约5微米和约200微米之间。
14.权利要求1的冶金粉末组合物,其中磁性或预磁性涂层的厚度在约5微米和40微米之间。
15.制备磁性压实的部件的方法,其包括:
提供含有铁基冶金粉末的粉末冶金组合物,其中铁基粉末的粒子涂覆有至少一种预磁性材料;
将粉末冶金组合物在模具中压实形成压实的金属部件;以及
将压实的金属部件退火形成磁性压实的部件。
16.权利要求15的方法,其中预磁性材料为预铁素体材料。
17.权利要求16的方法,其中预铁素体材料包含至少一种金属碳酸盐和/或金属卤化物。
18.权利要求15的方法,其中退火步骤使用高于1110°F的温度。
19.权利要求15的方法,其中退火步骤使用在约1110°F和约2370°F之间的温度。
20.权利要求15的方法,其中退火步骤使用保护性气氛。
21.权利要求15的方法,其中退火步骤使用氮气和氧气的气氛。
22.权利要求15的方法,其中退火步骤使用含有至少0.1%氧气的气氛。
23.权利要求15的方法,其中退火步骤使用氮气和约0.1%到约5%氧气的气氛。
24.根据权利要求15的方法制备的压实并退火的粉末冶金部件。
25.权利要求24的压实并退火的粉末冶金部件,其具有约1000μ的磁导率。
26.权利要求24的压实并退火的粉末冶金部件,其具有小于约3奥斯特的矫顽力。
27.权利要求24的压实并退火的粉末冶金部件,其具有约2奥斯特到约3奥斯特的矫顽力。
28.制备预磁性冶金粉末组合物的方法,其包括将铁基粉末与至少一种金属碳酸盐和/或金属卤化物的溶液混合。
29.权利要求28的方法,其中溶液用至少一种金属碳酸盐和/或金属卤化物饱和。
30.权利要求28的方法,其中溶剂为水或醇溶剂。
31.权利要求28的方法,其中铁基粉末包含占铁基粉末的至少约90重量%的铁。
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