CN105513737A - 一种不含重稀土元素烧结钕铁硼磁体的制备方法 - Google Patents

一种不含重稀土元素烧结钕铁硼磁体的制备方法 Download PDF

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CN105513737A
CN105513737A CN201610039324.5A CN201610039324A CN105513737A CN 105513737 A CN105513737 A CN 105513737A CN 201610039324 A CN201610039324 A CN 201610039324A CN 105513737 A CN105513737 A CN 105513737A
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rare earth
magnet
heavy rare
hours
preparation
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丁开鸿
彭众杰
王国海
陈秀雷
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Yantai Shougang Magnetic Materials Inc
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Yantai Shougang Magnetic Materials Inc
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Priority to JP2016214850A priority patent/JP6366666B2/ja
Priority to EP16202094.5A priority patent/EP3196896B1/en
Priority to US15/401,349 priority patent/US11062827B2/en
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Abstract

本发明公开了一种不含重稀土元素烧结钕铁硼磁体的制备方法，其特点是，使用平均粒径2.0～3.0μm磁粉制备钕铁硼磁体，通过细化晶粒，能有效增加磁体的形核场，提高矫顽力；通过控制润滑剂加入量，减少磁体中C、O、N含量，减少稀土元素损失，提高稀土利用率，可有效的提高磁体矫顽力和剩磁等磁性能；所用磁粉为一定含量的Pr-Nd、B、Al、Cu、Ga、Co以及余量为Fe的正常磁性粉体，成分中不含重稀土元素；相对于正常工艺使用平均粒度5.0μm左右的粉体制备毛坯，使用细粉压制的毛坯在烧结过程中能够显著降低烧结温度，抑制晶粒异常产生，提高磁性能，同时降低能耗；通过此方法，在不添加Dy、Tb等重稀土元素的条件下制备出高性能钕铁硼磁体，有效降低了高牌号钕铁硼磁体的生产成本。

Description

一种不含重稀土元素烧结钕铁硼磁体的制备方法
技术领域：
本发明涉及钕铁硼磁体技术领域，具体地讲是一种不含重稀土元素烧结钕铁硼磁体的制备方法。
背景技术：
钕铁硼磁体是目前性能最好的永磁材料，广泛应用于存储设备、电子元件、风力发电、电机等领域。但是钕铁硼磁材料具有较高的温度系数，即在高温下磁性能显著降低，低性能磁体难以满足永磁体在混合动力汽车、电机等领域的要求。
为了提高钕铁硼磁体的工作温度，目前常用的方法主要是提高居里温度、提高磁晶各向异性场、提高矫顽力等。居里温度和磁晶各向异性场属于材料的内禀特性，由材料成分决定，而传统提高矫顽力的方法往往以损失磁能积(BH)m为代价。现在提高矫顽力最有效的方法是通过添加重稀土元素Dy、Tb等，取代主相Nd2Fe14B中的Nd元素。Nd2Fe14B的磁晶各向异性场常数HA=5600KA/m，Dy2Fe14B的磁晶各向异性场常数HA=12000KA/m，Tb2Fe14B的磁晶各向异性场常数为HA=17600KA/m，由此可见，通过重稀土元素取代可以显著提高钕铁硼磁体的矫顽力。然而，重稀土元素储量及其有限，价格昂贵，既增加了磁体原料成本，也浪费了资源。为了降低重金属元素用量，采用晶界扩散方法对磁体进行重稀土元素渗透，但因扩散深度有限，该种方法仅适用于薄片磁体。中国专利ZL201110242847.7提到一种低镝含量高性能烧结钕铁硼的制备方法，该方法是以溅射沉积的方法将金属镝喷溅到粉体颗粒表面，这种方法较难控制Dy元素的分布及含量，同时操作方法比较复杂，成本较高。
另外，通过减小晶粒尺寸，改善晶界富钕相分布，可提高钕铁硼磁体的矫顽力，使钕铁硼磁体整体磁性能得到提高。但晶粒细化后，增加了磨粉、成型、热处理等工序的难度，磁体往往容易氧化、氮化，不易成型，晶粒异常生长，不利于磁体性能的提高。
发明内容：
本发明的目的是克服上述已有技术的不足，而提供一种不含重稀土元素烧结钕铁硼磁体的制备方法；主要解决现有的钕铁硼磁体的工作温度低的问题。
本发明的技术方案是：一种不含重稀土元素烧结钕铁硼磁体的制备方法，其特殊之处在于，它包括如下工艺步骤：
a按照重量百分比Pr-Nd为31%～34%，B为0.8%～1.2%，Al为0.4%～0.8%，Co为0.6%～1.2%，Cu为0.2%～0.5%，Ga为0.1%～0.4%，余量为Fe配置钕铁硼合金，并通过速凝薄带方法制备成厚度为0.1～0.6mm的薄片；
b将所得薄片进行氢爆处理，吸氢压力为0.15～0.3Mpa，吸氢时间为3.5小时，在550℃进行脱氢，得到合金粉末；
c在氢处理后的合金粉末中加入质量百分数为0.05%～0.5%的润滑剂，之后经流化床对撞式气流磨研磨至D50=2.0～3.0μm；
d在气流磨制备的粉体中加入质量百分数为0.03%～0.2%的润滑剂，在三维混料机中混料1～2小时；随后在磁场取向条件下进行压制成型，取向磁场为2.0～2.5T；
e将压制成型的毛坯在真空烧结炉中进行烧结，烧结温度为880℃～1030℃，烧结时间为6～15小时；待冷却后在780℃～860℃进行一级回火处理，保温时间为3小时；最后在480℃～550℃进行二级回火，保温时间为2～8小时；保温过程中真空度为5×10-2以下，得到无重稀土元素烧结钕铁硼磁体。
进一步的，c步骤中所述的流化床对撞式气流磨的研磨气体为氮气或氩气。
进一步的，所述的各工艺步骤中控制氧含量，使磁体中C、O、N含量满足1.2C+0.6O+N≤2800ppm。
本发明的一种不含重稀土元素烧结钕铁硼磁体的制备方法，原理是使用流化床对撞式气流磨将氢处理后的不含重稀土元素速凝薄片研磨至D50=2.0～3.0μm，加入一定含量的常规润滑剂后混料，然后在一定磁场取向条件下压制成型，最后在一定温度下进行热处理，得到高磁性能磁体。
本发明所述的一种不含重稀土元素烧结钕铁硼磁体的制备方法与已有技术相比具有突出的实质性特点和显著进步，1、在磁体制备过程中，不添加任何重稀土元素，而是通过细化晶粒、优化磁体显微结构的方式，提高磁体磁性能；2、通过控制配料成分、粉体粒度、热处理工艺、磁体中C、O、N含量等因素制备高磁性能钕铁硼磁体，有效降低了生产成本，避免了重稀土元素的消耗，节约了资源。
附图说明：
图1为实施例1所制备钕铁硼磁体的SEM照片；
图2为对比例1所制备钕铁硼磁体的SEM照片；
图3为实施例1中所制备钕铁硼磁体的磁性能曲线；
图4为对比例1中所制备钕铁硼磁体的磁性能曲线。
具体实施方式：
为了更好地理解与实施，下面结合实施例详细说明本发明。所举实施例仅用于解释本发明，并非用于限制本发明的范围。
实施例1，按照重量百分比Pr-Nd为32.5%，B为0.8%,Al为0.4%，Co为0.7%,Cu为0.3%，Ga为0.2%，余量为Fe配置钕铁硼合金，并通过速凝薄带方法制备成厚度范围为0.1～0.6mm的薄片；将所得薄片进行氢爆处理，吸氢压力为0.20Mpa，吸氢时间为3.5小时，之后在550℃进行脱氢，得到合金粉末；在氢处理后的合金粉末中加入质量百分数为0.1%的常规润滑剂，之后经流化床对撞式气流磨研磨至粉体粒度D50=2.8μm，流化床对撞式气流磨的研磨气体为氮气；在气流磨研磨细粉中加入质量百分数为0.05%的常规润滑剂，在三维混料机中混料2小时；随后在磁场取向条件下进行压制成型，取向磁场为2.0T；将压制成型后的毛坯在真空烧结炉中进行烧结，烧结温度为920℃，烧结时间为6小时；待冷却后在850℃进行一级回火处理，保温时间为3小时；最后在525℃进行二级回火，保温时间为2小时；保温过程中真空度为5×10-2以下；各工艺步骤中控制氧含量，使磁体中C、O、N含量满足1.2C+0.6O+N≤2800ppm；得到不含重稀土元素烧结钕铁硼磁体；磁体的SEM照片见图1，磁体的磁性能曲线见图3，具体磁性能见表1。
经过上述工艺制备的磁体，成分中不含重稀土元素，晶粒尺寸大部分位于2.1μm～4.3μm之间。磁体室温下内禀矫顽力达到1680KA/m,剩磁Br达到1.313T,最大磁能积(BH)max为334.6KJ/m3。
实施例2，按照重量百分比Pr-Nd为33%，B为0.9%,Al为0.6%，Co为0.7%,Cu为0.4%，Ga为0.15%，余量为Fe配置钕铁硼合金，并通过速凝薄带方法制备成厚度范围为0.1～0.6mm的薄片；将所得薄片进行氢爆处理，吸氢压力为0.20Mpa,吸氢时间为3.5小时，之后在550℃进行脱氢，得到合金粉末；在氢处理后的合金粉末中加入质量百分数为0.1%的常规润滑剂，经流化床对撞式气流磨研磨至粉体粒度D50=2.3μm；在气流磨研磨细粉中加入0.05%的常规润滑剂，在三维混料机中混料2小时；随后在磁场取向条件下进行压制成型，取向磁场为2.0T；将压制成型后的毛坯在真空烧结炉中进行烧结，烧结温度为900℃，烧结时间为10小时；待冷却后在850℃进行一级回火处理，保温时间为3小时；最后在525℃进行二级回火，保温时间为2小时；保温过程中真空度为5×10-2以下；各工艺步骤中控制氧含量，使磁体中C、O、N含量满足1.2C+0.6O+N≤2800ppm；得到不含重稀土元素烧结钕铁硼磁体；具体磁性能见表1。
经过上述工艺所制备的磁体，成分中不含重稀土元素，晶粒尺寸大部分位于2.0μm～4.2μm之间。磁体室温下内禀矫顽力Hcj达到1680KA/m,剩磁Br达到1.306T,磁能积(BH)max为330.8KJ/m3。
对比例1，按照重量百分比Pr-Nd为29.3%，Dy为2.0%，B为0.90%,Al为0.6%，Co为1.0%,Cu为0.25%，Ga为0.15%，余量为Fe配置钕铁硼合金，并通过速凝薄带方法制备成厚度范围为0.1～0.6mm的薄片；将所得薄片进行氢爆处理，吸氢压力为0.20Mpa,吸氢时间为3.5小时，之后在550℃进行脱氢，得到合金粉末；在氢处理后的合金粉末中加入质量百分数为0.1%的润滑剂，经流化床对撞式气流磨研磨至D50=4.7μm，在气流磨研磨细粉中加入0.09%的常规润滑剂，在三维混料机中混料2小时。随后在磁场取向条件下进行成型，取向磁场为2.0T；将成型后的毛坯在真空烧结炉中进行烧结，烧结温度为1010℃，烧结时间为6小时，待冷却至室温后在850℃进行一级回火处理，保温时间为3小时；最后在525℃进行二级回火，保温时间为8小时，得到重稀土镝质量分数为2%的烧结钕铁硼磁体；所制备磁体晶粒尺寸大部分位于4～8μm之间；磁体的SEM照片见图2，磁体的磁性能曲线见图4，具体磁性能见表1。
对比例2：按照重量百分比Pr-Nd为27.1%，Dy为4.0%，B为0.90%,Al为0.6%，Co为1.0%,Cu为0.25%，Ga为0.15%，余量为Fe配置钕铁硼合金，并通过速凝薄带方法制备成厚度范围为0.1～0.6mm的薄片；将所得合金薄片进行氢爆处理，吸氢压力为0.20Mpa,吸氢时间为3.5小时，之后在550℃进行脱氢，得到合金粉末；在氢处理后的合金粉末中加入质量百分数为0.1%的常规润滑剂，经流化床对撞式气流磨研磨至粉体粒度D50=4.7μm；在气流磨研磨细粉中加入0.09%的常规润滑剂，在三维混料机中混料2小时，随后在磁场取向条件下进行成型，取向磁场为2.0T；将成型后的毛坯在真空烧结炉中进行烧结，烧结温度为1010℃，烧结时间为6小时；待冷却后在850℃进行一级回火处理，保温时间为3小时；最后在525℃进行二级回火，保温时间为3小时，得到Dy质量分数为4%的烧结钕铁硼磁体，所制备磁体晶粒尺寸大部分位于4～8μm之间，具体磁性能见表1。
表1给出了四个案例中所制备磁体的详细性能。由表1及附图可见，实施例1、2的方法制备不含重稀土元素磁体，晶粒较对比例1和对比例2中磁体明显细化，且粒度分布更为均匀；就剩磁而言，四个案例中剩磁基本接近，而对于内禀矫顽力，实施例1、2所制备不含重稀土元素磁体的矫顽力比含质量分数分别为2%和4%重稀土镝的对比例1、2所制备磁体低103kA/m和207kA/m，且均达到了SH牌号。由此可见，本发明使用粉体粒度D50=2.0～3.0μm的气流磨细粉，控制常规润滑剂用量及各个工艺过程中氧含量，使得1.2C+0.6O+N≤2800ppm，同时采用适当热处理工艺，可以在不添加重稀土元素的情况下制备出高矫顽力的钕铁硼磁体，有效的减少了重稀土资源的损耗。
实施例3，按照重量百分比Pr-Nd为34%，B为0.8%，Al为0.4%，Co为0.6%，Cu为0.5%，Ga为0.4%，余量为Fe配置钕铁硼合金，并通过速凝薄带方法制备成厚度范围为0.1～0.6mm的薄片；将所得薄片进行氢爆处理，吸氢压力为0.15Mpa,吸氢时间为3.5小时，之后在550℃进行脱氢，得到合金粉末；在氢处理后的合金粉末中加入质量百分数为0.05%的常规润滑剂，之后经流化床对撞式气流磨研磨至粉体粒度D50=2.0μm，流化床对撞式气流磨的研磨气体为氮气；在气流磨研磨细粉中加入0.2%的常规润滑剂，在三维混料机中混料2小时；随后在磁场取向条件下进行压制成型，取向磁场为2.0T；将压制成型后的毛坯在真空烧结炉中进行烧结，烧结温度为880℃，烧结时间为15小时；待冷却后在780℃进行一级回火处理，保温时间为3小时；最后在480℃进行二级回火，保温时间为8小时；保温过程中真空度为5×10-2以下；各工艺步骤中控制氧含量，使磁体中C、O、N含量满足1.2C+0.6O+N≤2800ppm；得到不含重稀土元素烧结钕铁硼磁体。
实施例4，按照重量百分比Pr-Nd为31%，B为1.2%，Al为0.8%，Co为1.2%，Cu为0.2%，Ga为0.1%，余量为Fe配置钕铁硼合金，并通过速凝薄带方法制备成厚度范围为0.1～0.6mm的薄片；将所得薄片进行氢爆处理，吸氢压力为0.3Mpa，吸氢时间为3.5小时，之后在550℃进行脱氢，得到合金粉末；在氢处理后的合金粉末中加入质量百分数为0.5%的常规润滑剂，经流化床对撞式气流磨研磨至粉体粒度D50=3.0μm，流化床对撞式气流磨的研磨气体为氩气；在气流磨研磨细粉中加入0.03%的常规润滑剂，在三维混料机中混料1小时；随后在磁场取向条件下进行压制成型，取向磁场为2.5T；将压制成型后的毛坯在真空烧结炉中进行烧结，烧结温度为1030℃，烧结时间为6小时；待冷却后在860℃进行一级回火处理，保温时间为3小时；最后在550℃进行二级回火，保温时间为3小时；保温过程中真空度为5×10-2以下；各工艺步骤中控制氧含量，使磁体中C、O、N含量满足1.2C+0.6O+N≤2800ppm；得到不含重稀土元素烧结钕铁硼磁体。
以上所述，仅代表本发明的较好实施例，并非对本发明在任何形式上的限制，凡是依据本发明技术实质对本实施例进行的修改，均落入本发明的保护范围。

Claims (3)

1.一种不含重稀土元素烧结钕铁硼磁体的制备方法，其特征在于，它包括如下工艺步骤：
a按照重量百分比Pr-Nd为31%～34%，B为0.8%～1.2%，Al为0.4%～0.8%，Co为0.6%～1.2%，Cu为0.2%～0.5%，Ga为0.1%～0.4%，余量为Fe配置钕铁硼合金，并通过速凝薄带方法制备成厚度为0.1～0.6mm的薄片；
b将所得薄片进行氢爆处理，吸氢压力为0.15～0.3Mpa，吸氢时间为3.5小时，在550℃进行脱氢，得到合金粉末；
c在氢处理后的合金粉末中加入质量百分数为0.05%～0.5%的润滑剂，之后经流化床对撞式气流磨研磨至D50=2.0～3.0μm；
d在气流磨制备的粉体中加入质量百分数为0.03%～0.2%的润滑剂，在三维混料机中混料1～2小时；随后在磁场取向条件下进行压制成型，取向磁场为2.0～2.5T；
e将压制成型的毛坯在真空烧结炉中进行烧结，烧结温度为880℃～1030℃，烧结时间为6～15小时；待冷却后在780℃～860℃进行一级回火处理，保温时间为3小时；最后在480℃～550℃进行二级回火，保温时间为2～8小时；保温过程中真空度为5×10-2以下，得到无重稀土元素烧结钕铁硼磁体。
2.根据权利要求1所述的一种不含重稀土元素烧结钕铁硼磁体的制备方法，其特征在于，c步骤中所述的流化床对撞式气流磨的研磨气体为氮气或氩气。
3.根据权利要求1所述的一种不含重稀土元素烧结钕铁硼磁体的制备方法，其特征在于，所述的各工艺步骤中控制氧含量，使磁体中C、O、N含量满足1.2C+0.6O+N≤2800ppm。
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