CN108022710A - 铁基软磁非晶合金块材与制备方法及其应用 - Google Patents

铁基软磁非晶合金块材与制备方法及其应用 Download PDF

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CN108022710A
CN108022710A CN201611014964.7A CN201611014964A CN108022710A CN 108022710 A CN108022710 A CN 108022710A CN 201611014964 A CN201611014964 A CN 201611014964A CN 108022710 A CN108022710 A CN 108022710A
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iron
soft magnetic
based soft
amorphous metal
crystaline amorphous
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周力行
侯彦羽
杨智超
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Industrial Technology Research Institute ITRI
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Abstract

本发明公开一种铁基软磁非晶合金块材(Fe‑based amorphous soft magnetic bulk alloy)，其具有立体结构，此立体结构包括铁基软磁非晶合金组成物，此铁基软磁非晶合金组成物的化学式为FeaCobPcBdSie，其中76≤a≤80原子百分比(at％)，1≤b≤4at％，9≤c≤11at％，3≤d≤5at％，以及5≤e≤7at％。

Description

铁基软磁非晶合金块材与制备方法及其应用
【技术领域】
本公开涉及一种具有高磁通密度和高磁导率的金属软磁材料与制备方法及其应用，特别是涉及一种铁基软磁非晶合金块材(Fe-based amorphous soft magnetic bulkalloy)与制备方法及其应用。
【背景技术】
制备马达磁性元件的铁芯(iron-core)的理想材料必须具有高磁通密度和高磁导率。传统上是采用硅钢(silicon steel)来制作马达磁性元件的铁芯。然而，由于硅钢的片电阻率较低，仅能于较低频率的直流和交流电下运转。当操作频率增加，硅钢片铁芯的涡流损耗会急剧增加，造成能源转换效率降低。为了防止涡流产生或者减少涡流造成的能量损失，目前已有技术采用冲压成形的硅钢片与绝缘薄片或细丝相互堆迭形成铁心来制作马达磁性元件。但这种作法制程相当繁复，十分耗费加工成本，且尺寸不易微缩。
非晶质铁基软磁材料，具有高饱和磁通密度、高电阻率、低矫顽磁力等特点。目前已有技术将非晶质铁基软磁材料应用于马达磁性元件的制备，可有效降低涡流损及磁滞损。然而，受限于非晶质铁基软磁材料坚硬、易碎、难以进行切削与整平的材料特性，加工不易，也难以配合较复杂的元件磁路设计。另外，由于传统的非晶质铁基软磁材料一般以薄带铸造(tap casting)为主，有尺寸厚度的限制。再加上，又有材料耗损率偏高，卷绕后占积率偏低等缺点，使非晶质铁基软磁材料的应用范围受到相当大的限制。
因此，需要提供一种先进的铁基软磁非晶合金块材及其制备方法，来解决现有技术所面临的问题。
【发明内容】
本说明书中的一实施例提供一种铁基软磁非晶合金块材(Fe-based amorphoussoft magnetic bulk alloy)。其中，铁基软磁非晶合金块材具有立体结构，此立体结构包括铁基软磁非晶合金组成物，此铁基软磁非晶合金组成物的化学式为Fea Cob Pc Bd Sie，其中76≤a≤80原子百分比(at％)，1≤b≤4at％，9≤c≤11at％，3≤d≤5at％，以及5≤e≤7at％。
本说明书中的一实施例提供一种铁基软磁非晶合金块材的制作方法，所述方法包括下述步骤：首先提供如前所述的铁基软磁非晶合金组成物。之后，进行雾化制程(atomisation)，将铁基软磁非晶合金组成物碎化成复数个粉末颗粒。接着，将这些粉末颗粒烧结/熔融，以形成立体结构；再对此立体结构进行退火处理(annealing)。
根据上述，本说明书的实施例是揭露一种铁基软磁非晶合金块材及其制备方法。该方法先以雾化方法制作硅化及真圆度高的铁基软磁非晶合金粉体，再将铁基非晶合金粉体烧结/熔融制作成具有立体结构的磁性块材，可提高铁基非晶合金材料的厚度尺寸，增进其加工特性，并可配合更复杂的加工设计增加其应用范围。该磁性块材应用于马达磁性元件的铁芯中，可能提高磁性铁芯的磁通量(Φ＝Bs)和电阻值，降低磁性铁芯的矫顽磁力(coercivity，Hc)，减少马达磁性元件的涡流损耗。
【附图说明】
为了使本说明书的上述实施例及其他目的、特征和优点能更明显易懂，特举数个优选实施例，并配合所附图式，作详细说明如下:
图1为根据本说明书的一实施例所绘示的一种制作铁基软磁非晶合金块材的方法流程图；
图2A为根据本说明书的一实施例所绘示的一种用来实施雾化制程的装置结构示意图
图2B为绘示采用图1之步骤S2所制备而成的铁基软磁非晶合金粉末颗粒电子显微照片；
图3为根据本说明书的一实施例绘示采用图1之步骤S3所制备而成的立体结构制程结构剖面示意图；以及
图4为根据本说明书的一实施例绘示采用铁基软磁非晶合金块材所制备的马达磁性元件结构剖面示意图。
【附图标记说明】
100：铁基软磁非晶合金块材 201：融熔液体
202：流体 203：液滴
204：粉末颗粒 205：惰性气流
301：基材 301a：基材的表面
302：聚焦能量束 303：凸块
304：网格结构 305：扫描路径
400：马达磁性元件 401：铁芯定子
402：转子 402a：盘状金属被铁
402b：磁石 403：转轴
404：底座 ：非平角
S1：提供一种铁基软磁非晶合金组成物
S2：将铁基软磁非晶合金组成物碎化成复数个粉末颗粒
S3：将粉末颗粒烧结/熔融以形成立体结构
S4：对此立体结构进行退火处理
【具体实施方式】
本说明书所揭露的实施例涉及一种铁基软磁非晶合金块材及其制备方法，可解决现有技术的马达磁性元件采用硅钢铁芯造成涡流损耗过大，以及采用铁基软磁非晶合金材料加工特性不佳的问题。为让本说明书的上述目的、特征和优点能更明显易懂，特举数个优选实施例，并配合所附图式详细描述如下。
但必须注意的是，这些特定的实施案例与方法并非用以限定本发明。本发明仍可采用其他特征、元件、方法及参数来加以实施。优选实施例的提出仅用以例示本发明的技术特征，并非用以限定本发明的申请专利范围。本领域的技术人员将可根据以下说明书的描述，在不脱离本发明的精神范围内，作均等的修饰与变化。在不同实施例与图式之中，相同的元件，将以相同的附图标记加以表示。
请参照图1，图1为根据本说明书的一实施例所绘示的一种制作铁基软磁非晶合金块材100的方法流程图。制作铁基软磁非晶合金块材100的方法包括下述步骤：首先提供一种铁基软磁非晶合金组成物(如步骤S1所述)。其中，此铁基软磁非晶合金组成物的化学式为Fea Cob Pc Bd Sie，其中76≤a≤80原子百分比(at％)，1≤b≤4at％，9≤c≤11at％，3≤d≤5at％，以及5≤e≤7at％。然而铁基软磁非晶合金组成物的铁(Fe)、钴(Co)、磷(P)、硼(B)和硅(Si)的原子百分比a、b、c、d和e并不以此为限。例如，在本说明书的一些实施例中，76≤a≤78at％，2≤b≤4at％，9≤c≤11at％，3≤d≤5at％，以及5≤e≤7at％。
之后，进行雾化制程，将铁基软磁非晶合金组成物碎化成复数个粉末颗粒204(如步骤S2所述)。请参照图2A，图2A为根据本说明书的一实施例所绘示的一种用来实施雾化制程的装置结构示意图。其中，雾化制程包括下述步骤：先对铁基软磁非晶合金组成物进行熔炼(melting)制程，使铁基软磁非晶合金组成物形成融熔液体201。之后，藉由流体202，例如水流或气流，将该融熔液体碎化成复数个液滴203，并藉由水流或气流将这些液滴冷却凝固形成复数个粉末颗粒204。
请参照图2B，图2B为绘示采用图1的步骤S2所制备而成的铁基软磁非晶合金粉末颗粒204的电子显微照片。其中，铁基软磁非晶合金粉末颗粒204的平均粒径实质介于25微米(μm)至70微米之间。且铁基软磁非晶合金粉末颗粒204的真圆度相当高。在本实施例之中铁基软磁非晶合金粉末颗粒204的平均粒径实质为35微米。
在本说明书的一些实施例中，雾化制程可以选自于水雾化法、气雾化法、离心雾化法以及超声波脉冲惰性气体雾化法。在本实施例中，采用高纯氩气气流202来将铁基软磁非晶合金组成物的融熔液体201雾化成细小液滴203，并在重力作用下降落经过惰性气流205，使其冷却凝固形成复数个粉末颗粒204。
表一例示采用前述方法所制作而成的铁基软磁非晶合金粉末颗粒204的多个实施例，并测量铁基软磁非晶合金粉末颗粒204的磁通量和矫顽磁力。
表一
接着，将这些粉末颗粒烧结/熔融，以形成立体结构(如步骤S3所述)。请参照图3，图3为根据本说明书的一实施例绘示采用图1的步骤S3所制备的立体结构的制程结构剖面示意图。其中，立体结构的形成包括下述步骤：将粉末颗粒204覆盖于基材301的表面301a上。再提供聚焦能量束302沿着预设的扫描路径305对这些粉末颗粒204进行烧结/熔融，以形成复数个凸块303与基材表面301a夹为非平角，藉以在基材表面301a定义出网格结构304。
在本说明书的一些实施例中，基材301可以是一种硬质或可挠性的金属基板。聚焦能量束302可以是一种激光光束。在本实施例中，是采用功率实质介于200瓦特(W)至340瓦特、扫描速度实质介于1500毫米/秒(mm/s)至4500毫米/秒的激光光束，对这些粉末颗粒204进行烧结/熔融，而在金属基板上形成网格结构304。其中，网格结构304可以是一种单层结构，或多层堆迭结构。且网格结构304的厚度实质大于2厘米(cm)。
后续，再对此立体结构304进行退火处理(annealing)(如步骤S4所述)，完成铁基软磁非晶合金块材100的制备。在本说明书的一些实施例中，退火处理于空气气氛(airatmosphere)中进行，处理时间实质介于0.5小时至2小时之间，且退火温度实质介于300℃至600℃。
采用前述方法所制作而成的铁基软磁非晶合金块材100不仅具有立体结构，其饱和磁通量(Φ＝Bs)、电阻和矫顽磁力也与相同材质的铁基软磁非晶合金粉末颗粒204不同。在本说明书的一些实施例中，铁基软磁非晶合金块材100的饱和磁通量实质大于1.3特斯拉(Tesla)至1.7特斯拉；矫顽磁力实质介于8A/m至16A/m；电阻实质为200(μΩ-cm)。
表二例示说明采用前述方法所制作而成的铁基软磁非晶合金块材100的多个实施例：
表二
将具有立体结构的铁基软磁非晶合金块材100(如表二所例示)与表一所对应例示的铁基软磁非晶合金粉末颗粒204进行比较，可以发现：虽然二者皆是采用相同的铁基软磁非晶合金材料所构成，但二者具有不同的饱和磁通量、不同的矫顽磁力和不同的电阻。其中，铁基软磁非晶合金块材100具有较大的饱和磁通量和电阻以及较小的矫顽磁力。
其中，又以实施例4(包含Fe77Co3P10B4Si6的铁基软磁非晶合金块材100)所具备的饱和磁通量、矫顽磁力以及电阻的参数条件，最适合应用于制备马达磁性元件的铁芯。请参照图4，图4为根据本说明书的一实施例绘示采用铁基软磁非晶合金块材100所制备的马达磁性元件400的结构剖面示意图。在本实施例中，马达磁性元件400可以是一种轴向式马达，其包括铁芯定子401、转子402和线圈403。其中，铁芯定子401是由铁基软磁非晶合金块材100所制成的盘式结构，固设于底座404上。转子402包括套设于铁芯定子401外侧的盘状金属被铁402a，以及设于盘状金属被铁402a与铁芯定子401之间的磁石402b。转子402与转轴403连结，且可转动地同轴装设于底座404和铁芯定子401之中。藉由外部导线(未绘示)提供电力流入缠绕于铁芯定子401上的线圈(未绘示)产生磁场，使铁芯定子401形成电磁铁，藉由电磁铁与转子402的磁石402b间的磁力作功，带动转轴403同轴转动。
再将采用前述实施例的铁基软磁非晶合金块材100所做成的铁芯定子401与现有技术的采用冷轧硅钢片和铁基软磁非晶合金铸造薄带的比较例1和比较例2(如表三所例示)所做成的铁芯定子做比较，可以发现：采用铁基软磁非晶合金块材100的铁芯定子401具有比现有技术的冷轧硅钢片和铁基软磁非晶合金铸造薄带所做成的铁芯定子更大的饱和磁通量和电阻以及较小的矫顽磁力，可以大于减少马达磁性元件400的涡流损耗。
表三
另外，由于铁基软磁非晶合金块材100具有厚度实质大于2厘米的立体网格结构304。因此，比传统的铁基软磁非晶合金铸造薄带具有更强的韧性抗，可以抵抗加工时的机械应力，能配合更复杂的结构设计进行加工，有助于拓展其他领域的应用。在本说明书的一些实施例中，铁基软磁非晶合金块材100具有实质为950Hv的硬度以及实质为2800MPa的抗拉强度。
根据上述，本说明书的实施例是揭露一种铁基软磁非晶合金块材及其制备方法。所述方法先以雾化方法制作硅化及真圆度高的铁基软磁非晶合金粉体，再将铁基非晶合金粉体烧结/熔融制作成具有立体结构的磁性块材，可提高铁基非晶合金材料的厚度尺寸，增进其加工特性。并可配合更复杂的加工设计增加其应用范围。所述磁性块材应用于马达磁性元件的铁芯中可提高磁性铁芯的磁通量(Φ＝Bs)和电阻值，降低磁性铁芯的矫顽磁力(coercivity，Hc)，减少马达磁性元件的涡流损耗。
综上所述，虽然本说明书已以优选实施例揭露如上，然其并非用以限定本发明。本发明所属技术领域的技术人员在不脱离本发明的精神和范围内，应可作各种更动与润饰。因此，本发明飞保护范围应以所附权利要求书界定的范围为准。

Claims (11)

1.一种铁基软磁非晶合金块材(Fe-based amorphous soft magnetic bulk alloy)，其具有立体结构，该立体结构包括铁基软磁非晶合金组成物，该铁基软磁非晶合金组成物的化学式为Fea Cob Pc Bd Sie，其中76≤a≤80原子百分比(at％)，1≤b≤4at％，9≤c≤11at％，3≤d≤5at％，以及5≤e≤7at％。
2.如权利要求1所述的铁基软磁非晶合金块材，其中76≤a≤78at％，2≤b≤4at％，9≤c≤11at％，3≤d≤5at％，以及5≤e≤7at％。
3.如权利要求1所述的铁基软磁非晶合金块材，其中该立体结构为网格(grid)结构。
4.如权利要求1所述的铁基软磁非晶合金块材，其中该立体结构具有实质大于2厘米(cm)的厚度。
5.如权利要求1所述的铁基软磁非晶合金块材，其中该立体结构具有实质大于1.3特斯拉(Tesla)至1.7特斯拉的饱和磁通量(Φ＝Bs)，实质为8A/m至16A/m的矫顽磁力(coercivity，Hc)以及实质为200(μΩ-cm)的电阻。
6.一种铁基软磁非晶合金块材的制作方法，包括：
提供如权利要求1所述的铁基软磁非晶合金组成物；
进行雾化制程(atomisation)，将该铁基软磁非晶合金组成物碎化成复数个粉末颗粒；
烧结/熔融所述粉末颗粒，以形成立体结构；以及
对该立体结构进行退火处理(annealing)。
7.如权利要求6所述的铁基软磁非晶合金块材的制作方法，其中该雾化制程包括：
进行熔炼(melting)制程，使该铁基软磁非晶合金组成物形成融熔液体；
藉由一流体将该融熔液体碎化成复数个液滴；以及
冷却凝固所述液滴，以形成所述粉末颗粒。
8.如权利要求6所述的铁基软磁非晶合金块材的制作方法，其中该立体结构的形成，包括：
将所述粉末颗粒覆盖于基材表面上；以及
提供聚焦能量束沿着预设扫描路径对所述粉末颗粒进行烧结/熔融，以形成复数个凸块与该基材表面夹为非平角，藉以定义出网格结构。
9.如权利要求8所述的铁基软磁非晶合金块材的制作方法，其中该聚焦能量束包括激光光束，该激光光束具有实质为200瓦特(W)至340瓦特的功率，以及实质为1500毫米/秒(mm/s)至4500毫米/秒的扫描速度。
10.如权利要求6所述的铁基软磁非晶合金块材的制作方法，其中该退火处理是在空气气氛(air atmosphere)中进行，处理时间实质为0.5小时至2小时，且退火温度实质为300℃至600℃。
11.一种电磁机电装置，包括：
定子，包含如权利要求1所述的铁基软磁非晶合金块材所制成的永久磁铁；
转子，可转动地同轴装设于该定子之中；以及
线圈，绕组于该转子上。
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