CN103295761A - 磁铁的制造方法和磁铁 - Google Patents
磁铁的制造方法和磁铁 Download PDFInfo
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Abstract
本发明涉及磁铁的制造方法和磁铁。该磁铁的制造方法中将含有轻稀土元素作为R的R-Fe-N系化合物的原材料粉末或Fe-N系化合物的原材料粉末压缩成型为规定形状。然后,将成型的原材料粉末的成型体在氧化性气氛下加热,利用在加热后的原材料粉末中生成的氧化膜使原材料粉末彼此接合。
Description
技术领域
本发明涉及一种磁铁的制造方法和磁铁。
背景技术
迄今为止,作为高性能的磁铁已使用钕磁铁(Nd-Fe-B系磁铁)。但是,就钕磁铁的高性能化而言,由于使用昂贵且稀少的镝(Dy),所以近年来正在进行不使用镝的磁铁的开发。
作为不使用镝的磁铁,已知有Sm-Fe-N系磁铁。Sm-Fe-N系化合物由于分解温度低,所以难以适用高温烧结。如果在分解温度以上进行烧结,则化合物分解,无法发挥作为磁铁的性能。因此,利用粘合剂来接合。但是,使用粘合剂会使磁铁的密度降低,是使剩余磁通密度降低的原因。
另外,在日本特开2005-223263号公报中记载了使Sm-Fe-N系化合物粉末上形成氧化被膜后,在非氧化气氛中预备压缩成型为规定形状,接着在非氧化气氛中、在350~500℃的温度下进行压密化,由此制造稀土永久磁铁。由此,能够在低于分解温度的条件下制造Sm-Fe-N系磁铁。
但是,氧化被膜是使剩余磁通密度降低的原因。因此,如果在所有的化合物粉末的表面形成氧化被膜,则剩余磁通密度降低。
发明内容
本发明的目的之一在于提供一种不使用镝、不使用粘合剂且能够得到高剩余磁通密度的磁铁的制造方法和磁铁。
本发明涉及的磁铁的制造方法,具备成型工序和氧化煅烧工序,上述成型工序是将含有轻稀土元素作为R的R-Fe-N系化合物的原材料粉末或Fe-N系化合物的原材料粉末压缩成型为规定形状的工序,上述氧化煅烧工序是将成型的上述原材料粉末的成型体在氧化性气氛下加热,利用在上述原材料粉末上生成的氧化膜使上述原材料粉末彼此接合的工序。
附图说明
以下,参照附图对本发明的实施方式进行说明,本发明的上述内容、特征及优点会变得更加清楚,其中,相同的符号代表相同的要素,其中,
图1是表示本实施方式的磁铁的制造方法的流程图。
图2是图1所示的氧化煅烧工序的热处理工序图。
图3是图1的氧化煅烧工序前的组织截面模式图。
图4是图1的氧化煅烧工序后的组织截面模式图。
图5是本实施例的氧化煅烧工序前的表面的显微镜照片(×8000)。
图6是本实施例的氧化煅烧工序后的表面的显微镜照片(×8000)。
具体实施方式
参照图1~图4,对本实施方式的磁铁的制造方法进行说明。如图1所示,将磁铁的原材料粉末压缩成型为规定形状(步骤S1,成型工序)。在此,在磁铁的原材料粉末中,使用含有轻稀土元素作为R的R-Fe-N系化合物或Fe-N系化合物。作为轻稀土元素R,优选为Sm。即,在磁铁的原材料粉末中优选使用Sm2Fe17N3或Fe16N2。
该成型体的组织截面的模式图如图3所示。在成型工序中成型的成型体中,原材料粉末10为完全未变形或因压缩而轻微变形的程度。因此,虽然原材料粉末10彼此部分接触,但在原材料粉末10彼此之间形成了空隙20。在此,在氧化性气氛下将成型体成型即可。由此,氧化性气体进入该空隙20中。应予说明,在成型工序中,不使用粘合剂等粘接剂。因此,在该成型体中,原材料粉末10彼此的结合力小。
在此,例如使用Sm2Fe17N3的原材料粉末10时,原材料粉末10的平均粒径为3μm左右,成型体的最小厚度为2mm左右,用于将成型体成型的加压力为50MPa左右。另外,例如使用Fe16N2的原材料粉末10时与使用Sm2Fe17N3的原材料粉末10时为相同的程度。
接着,将成型工序中成型的成型体在氧化性气氛下加热(步骤S2,氧化煅烧工序)。该氧化煅烧工序在利用微波的加热炉、电炉、等离子体加热炉、高频淬火炉、利用红外线加热器的加热炉等中配置成型体而进行。该煅烧工序中的热处理工序如图2所示。
加热温度Te1设定为低于原材料粉末的化合物的分解温度Te2。例如,使用Sm2Fe17N3的原材料粉末10时,分解温度Te2为500℃左右,所以将加热温度Te1设定为低于500℃。例如,设定为200℃左右。另外,使用Fe16N2的原材料粉末时也同样。
另外,氧化性气氛的氧浓度和气压只要能够将原材料粉末氧化即可,如果是大气中的氧浓度程度和大气压程度就是充分的。因此,无需特别地管理氧浓度、气压等。因此,在大气气氛下加热即可。并且,通过将加热温度Te1设为200℃左右,从而在Sm2Fe17N3的原材料粉末或Fe16N2的原材料粉末的任一情况下均能够形成氧化膜。
氧化煅烧工序后的成型体的组织截面的模式图如图4所示。通过在氧化性气氛下加热,从而原材料粉末30的露出面与氧发生化学反应,形成氧化膜32(由图4的粗线表示)。该氧化膜32使邻接的原材料粉末30彼此接合,能够充分确保成型体的强度。
在此,在氧化煅烧工序前的成型体中,如图3所示,原材料粉末10部分接触,在原材料粉末10之间形成了空隙20。然后,在氧化煅烧工序中,于在该空隙20露出的表面侧形成氧化膜32,氧化膜32使邻接的原材料粉末30彼此接合。即,氧化膜32在原材料粉末30中形成于在空隙20中露出的部分,在原材料粉末30中,在空隙20中未露出的部分为母材31本身。因此,不在各原材料粉末30的所有的表面上形成氧化膜32。由此,只要能够充分确保原材料粉末30彼此的接合强度,就尽可能少地形成氧化膜32,所以能够抑制伴随着氧化膜32的形成而降低磁铁的剩余磁通密度。因此,能够制造廉价且高性能的磁铁。
此外,根据上述制造方法,由于使用R-Fe-N系化合物或Fe-N系化合物,所以可以不使用镝。因此,能够廉价地制造磁铁。另外,R-Fe-N系化合物或Fe-N系化合物由于分解温度低,所以难以高温烧结,但在氧化煅烧工序中,在低于该化合物的分解温度Te2下进行加热,所以能够防止该化合物分解。因此,通过化合物的分解而能够防止降低磁铁的剩余磁通密度。其结果,能够可靠地制造高剩余磁通密度的磁铁。
实施例
作为原材料粉末,使用日本特开2000-104104号公报中记载的日亚化学工业社制的Sm2Fe17N3。具体而言,使用平均粒径3μm的Sm2Fe17N3,在非加热成型工序中的成型体为10mm×30m×2mm的长方体,用磁场取向加压进行加压成型,其加压力为50MPa。然后,氧化煅烧工序是在大气气氛中、电炉内加热成型体。对于加热处理工序,将加热温度Te1设为200℃、将升温速度设为2.25℃/min。
如上所述制造磁铁时,氧化煅烧工序前的表面照片如图5所示,氧化煅烧工序后的表面照片如图6所示。如果图5与图6相比,则图5的粉末的表面凹凸较少,与此相对,在图6的粉末的表面遍布网眼状的凸起。认为该网眼状的凸起为氧化膜32。并且,可知图6中的网眼将相邻的粉末彼此连结。由此,通过氧化膜32而使原材料粉末10彼此一体地接合。
并且,氧化煅烧后的成型体的强度用抗折试验进行了评价,结果为2.0MPa。另外,剩余磁通密度用振动试样型磁力计(VSM,VibratingSample Magnetometer)进行了评价,结果为1.0T。由此,可知能够得到充分的强度和剩余磁通密度。
Claims (4)
1.一种磁铁的制造方法,其特征在于,具备以下工序:
成型工序,将含有轻稀土元素作为R的R-Fe-N系化合物的原材料粉末或Fe-N系化合物的原材料粉末压缩成型为规定形状,和
氧化煅烧工序,将成型的所述原材料粉末的成型体在氧化性气氛下加热,利用在所述原材料粉末上生成的氧化膜使所述原材料粉末彼此接合。
2.根据权利要求1所述的磁铁的制造方法,其中,所述氧化煅烧工序为在低于所述R-Fe-N系化合物或所述Fe-N系化合物的分解温度下对所述成型体进行加热。
3.根据权利要求1或2所述的磁铁的制造方法,其中,所述轻稀土元素R为Sm。
4.一种磁铁,其特征在于,通过以下制造方法制成:将含有轻稀土元素作为R的R-Fe-N系化合物的原材料粉末或Fe-N系化合物的原材料粉末压缩成型为规定形状,将成型的原材料粉末的成型体在氧化性气氛下加热,利用在所述原材料粉末上生成的氧化膜使所述原材料粉末彼此接合。
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US20140374643A1 (en) * | 2013-06-25 | 2014-12-25 | Jtekt Corporation | Magnet manufacturing method and magnet |
JP6894521B2 (ja) | 2017-09-25 | 2021-06-30 | 株式会社Kokusai Electric | 基板処理装置、石英反応管、クリーニング方法並びにプログラム |
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CN106024270A (zh) * | 2015-03-31 | 2016-10-12 | 太阳诱电株式会社 | 线圈部件 |
CN106024270B (zh) * | 2015-03-31 | 2018-02-23 | 太阳诱电株式会社 | 线圈部件 |
US10566118B2 (en) | 2015-03-31 | 2020-02-18 | Taiyo Yuden Co., Ltd. | Coil component |
CN107160672A (zh) * | 2016-03-07 | 2017-09-15 | 精工爱普生株式会社 | 三维造型物的制造方法、制造装置以及三维造型物 |
CN107160672B (zh) * | 2016-03-07 | 2021-05-07 | 精工爱普生株式会社 | 三维造型物的制造方法、制造装置以及三维造型物 |
Also Published As
Publication number | Publication date |
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US20130222094A1 (en) | 2013-08-29 |
EP2631918A2 (en) | 2013-08-28 |
JP2013175650A (ja) | 2013-09-05 |
EP2631918A3 (en) | 2013-12-04 |
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