CN105855555B - 一种铁钴软磁合金器件的制备方法 - Google Patents

一种铁钴软磁合金器件的制备方法 Download PDF

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CN105855555B
CN105855555B CN201610205538.5A CN201610205538A CN105855555B CN 105855555 B CN105855555 B CN 105855555B CN 201610205538 A CN201610205538 A CN 201610205538A CN 105855555 B CN105855555 B CN 105855555B
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刘志坚
陈远星
吴水桂
何坤宏
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Abstract

本发明公开一种铁钴软磁合金器件的制备方法，其步骤是：1.采用真空速凝铸片炉将工业纯铁、金属钴、金属钒和稀土等材料熔化、精炼，采用速凝快淬技术制造出由含Co 35.0～50%、V0.5～1.5%、稀土0.06～0.10%，其余为Fe的铁钴合金薄片，再磨成粉末；2.将该粉末与雾化法制出的铁钴合金粉末按照3～8:10的比例混合；3.按聚乙烯醇水溶液：铁钴合金粉末重量比例为3～7：2000，搅拌均匀，然后炒干；4.采用高速压机将合金粉末压制成形制备压坯；5.将压坯进行烧结热处理：在炉内通入氢气，温度为1000～1200℃，保温时间为5～9小时，然后随炉冷却至室温出炉。按本制备方法制备出的铁钴软磁合金器件具有高致密度和高磁性能的优点。

Description

一种铁钴软磁合金器件的制备方法
技术领域
本发明涉及金属材料加工技术领域，特别是一种适合制造形状复杂、高致密度和高磁性能的铁钴软磁合金器件的制备方法。
背景技术
铁钴软磁合金是重要的金属软磁材料,具有良好的磁性能,广泛应用于变压器、电动机、电话机膜片、高速打印机嵌铁、接收机线圈、开关和存储铁芯、磁致伸缩传感器、电磁铁极头等。随着电子工业的快速发展,电子器件的设计制造逐渐向小型化、集成化、多功能化方向发展,所用的软磁合金器件尺寸精度越来越高，形状变得越来越复杂。
铁钴软磁合金器件通常采用传统的熔锻轧法制出材料再机加工，生产工序多，生产效率低，因铁钴软磁合金材料硬且脆，加工成材率低，原材料浪费大，生产周期长，成本高，产品价格昂贵，导致材料使用范围较窄，无法大范围推广应用，铁钴软磁合金良好的材料特性未能充分发挥。
粉末冶金工艺是一种高自动化、大规模生产异形产品的近净成形制备技术,它以粉末为原料，通过成形、烧结以及后继处理制出产品，在软磁合金器件的制备中开始应用。但采用粉末冶金工艺具制备铁钴软磁合金器件时，由于工艺的限制存在一定的孔隙，密度不高，组织缺陷等问题，造成材料的磁性能不理想。
上述问题是现有技术生产铁钴软磁合金器件一直存在的不足之处。
发明内容
本发明的目的在于针对现有铁钴软磁合金器件制备存在的上述问题，提供一种可以制备出复杂形状、高致密度和高磁性能的铁钴软磁合金器件的制备方法。
上述任务是这样实现的：
1.采用真空速凝铸片炉将工业纯铁、金属钴、金属钒和稀土等材料熔化、精炼和速凝快淬技术制造出由重量百分比的Co 35.0～50%、V 0.5～1.5%、稀土0.06～0.10%，其余为Fe组成的铁钴合金薄片，然后经环锤磨机磨成快淬铁钴合金粉末；
2.将制成的快淬铁钴合金粉末与雾化法制出的雾化铁钴合金粉末按照3～8:10的比例混合均匀,制备成铁钴合金混合粉末；
3. 按聚乙烯醇水溶液（溶液中聚乙烯醇重量占比为4～6%）：铁钴合金粉末重量比例为3～7：2000，将聚乙烯醇水溶液加入到铁钴合金混合粉末中并搅拌均匀，然后炒干，制得粘结合金粉末；
4. 通过高速压机采用高速压制技术将粘结合金粉末压制成形制备压坯，其冲击速度为7.8～9.5米/秒；
5.将压坯放入保护气氛炉内进行烧结热处理：在炉内通入氢气，温度为1000～1200℃，保温时间为5～9小时。然后随炉冷却，冷至室温出炉，得到所需的器件。
上述的铁钴合金器件的制备方法还可采取如下措施进一步完善：
1.所述的铁钴合金优选成分由重量百分比的Co 35.0～40.0%、钒 0.7～1.0%、稀土镧0.06～0.08%，其余为铁组成。
2.所述的快淬铁钴软磁合金粉末与雾化铁钴软磁合金粉末优选按3:5的比例配粉混合。
3.所述的在铁钴合金混合粉末中加入聚乙烯醇水溶液，优选按聚乙烯醇水溶液：铁钴合金粉末重量比例为1:400。
本发明的有益效果在于：采用速凝快淬制粉和雾化法等不同制粉方式制备出铁钴合金混合粉末，加入合适的粘接剂混合均匀，通过高速压制成形制备压坯，进行保护气氛烧结，制备出器件。将两种不同制备方式合金粉末按一定比例经充分混合，可充分利用两种方式合金粉末的优点，成形时使用的粘结剂量更少，有效降低杂质含量，提高产品综合性能，可以制备出复杂形状、高致密度和高磁性能的铁钴软磁合金器件。经测试，铁钴软磁合金的饱和磁感应强度B值≥2.10 T（特斯拉）。
具体实施方式
下面通过具体实施例对本发明作进一步的说明：
实施例1
本发明实施例1包括以下步骤：
1. 采用真空速凝铸片炉将工业纯铁、金属钴、金属钒和稀土等材料熔化、精炼，采用速凝快淬技术制出由重量百分比的Co 36%、V 0.8%、稀土镧0.065%，其余为Fe组成的铁钴合金薄片，然后经环锤磨机磨成快淬铁钴合金粉末；
2. 将制成的快淬铁钴合金粉末与雾化铁钴合金粉末按照3:10 的比例混合均匀后,制备成铁钴合金混合粉末；
3. 按聚乙烯醇水溶液（溶液中聚乙烯醇重量占比为4%）：铁钴合金粉末重量比例为3：2000，将聚乙烯醇水溶液加入到铁钴合金混合粉末中并搅拌均匀，然后炒干，制得粘结合金粉末；
4. 采用高速压机将合金粉末压制成形制备压坯，其冲击速度为8.0米/秒；
5. 将压坯放入保护气氛炉内进行烧结热处理：在炉内通入氢气，温度为1050℃，保温时间为9小时。然后随炉冷却，冷至室温出炉，得到所需的器件。
检测铁钴合金材料性能：饱和磁感应强度B值为2.11 T（特斯拉）。
实施例2
1. 采用真空速凝铸片炉将工业纯铁、金属钴、金属钒和稀土等材料熔化、精炼，采用速凝快淬技术制出由重量百分比的Co 40.0%、V 1.0%、稀土镧0.08%，其余为Fe组成的铁钴合金薄片，然后经环锤磨机磨成快淬铁钴合金粉末；
2. 将制成的快淬铁钴合金粉末与雾化制出的铁钴合金粉末按照3:5 的比例混合均匀后, 制备成铁钴合金混合粉末；
3. 按聚乙烯醇水溶液（溶液中聚乙烯醇重量占比为5%）：铁钴合金粉末重量比例为1：400，将聚乙烯醇水溶液加入到铁钴合金混合粉末中并搅拌均匀，然后炒干，制得粘结合金粉末；
4. 采用高速压机将合金粉末压制成形制备压坯，其冲击速度为8.9米/秒；
5. 将压坯放入保护气氛炉内进行烧结热处理：在炉内通入氢气，温度为1150℃，保温时间为8.5小时。然后随炉冷却，冷至室温出炉，得到所需的器件。检测铁钴合金材料性能：饱和磁感应强度B值为2.17 T（特斯拉）。
实施例3
1. 采用真空速凝铸片炉将工业纯铁、金属钴、金属钒和稀土等材料熔化、精炼，采用速凝快淬技术制出由重量百分比的Co 50.0%、V 1.5%、稀土镧0.1%，其余为Fe组成的铁钴合金薄片，然后经环锤磨机磨成快淬铁钴合金粉末；
2. 将制成的快淬铁钴合金粉末与雾化制出的铁钴合金粉末按照4:5 的比例混合均匀后, 制备成铁钴合金混合粉末；
3. 按聚乙烯醇水溶液（溶液中聚乙烯醇重量占比为6%）：铁钴合金粉末重量比例为7：2000，将聚乙烯醇水溶液加入到铁钴合金混合粉末中并搅拌均匀，然后炒干，制得粘结合金粉末；
4. 采用高速压机将合金粉末压制成形制备压坯，其冲击速度为9.5米/秒；
5. 将压坯放入保护气氛炉内进行烧结热处理：在炉内通入氢气，温度为1200℃，保温时间为5小时。然后随炉冷却，冷至室温出炉，得到所需的器件。检测铁钴合金材料性能：饱和磁感应强度B值为2.14 T（特斯拉）。

Claims (3)

1.一种铁钴软磁合金器件的制备方法，其特征在于：
(1)采用真空速凝铸片炉将工业纯铁、金属钴、金属钒和稀土材料熔化、精炼，采用速凝快淬技术制造出由重量百分比的Co 35.0～50％、V 0.5～1.5％、稀土0.06～0.10％，其余为Fe组成的铁钴合金薄片，然后经环锤磨机磨成快淬铁钴合金粉末；
(2)将制成的快淬铁钴合金粉末与雾化制出的铁钴合金粉末按照3～8:10的比例混合均匀后,制备成铁钴合金混合粉末；
(3)按聚乙烯醇水溶液：铁钴合金粉末重量比例为3～7：2000，其中聚乙烯醇水溶液中聚乙烯醇重量占比为4％～6％，将聚乙烯醇水溶液加入到铁钴合金混合粉末中并搅拌均匀，然后炒干，制得粘结合金粉末；
(4)通过高速压机采用高速压制技术将粘结合金粉末压制成形制备压坯，其冲击速度为7.8～9.5m/s；
(5)将压坯放入保护气氛炉内进行烧结热处理：在炉内通入氢气，温度为1000～1200℃，保温时间为5～9小时，然后随炉冷却，冷至室温出炉，得到所需的器件。
2.根据权利要求1所述的铁钴软磁合金器件的制备方法，其特征是铁钴合金混合粉末是采用真空速凝铸片炉冶炼和环锤磨机制出的快淬铁钴软磁合金粉末与雾化铁钴软磁合金粉末进行混合，按3～8:10的比例配粉混料。
3.根据权利要求1所述的铁钴软磁合金器件的制备方法，其特征是粘结合金粉末是按聚乙烯醇水溶液：铁钴合金粉末重量比例为3～7：2000，其中聚乙烯醇水溶液中聚乙烯醇重量占比为4％～6％，将聚乙烯醇水溶液加入到铁钴合金混合粉末中并搅拌均匀，然后炒干制成。
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