CN109108238B - 一种高电阻率铁基纳米晶合金薄带制备方法 - Google Patents

一种高电阻率铁基纳米晶合金薄带制备方法 Download PDF

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CN109108238B
CN109108238B CN201811103803.4A CN201811103803A CN109108238B CN 109108238 B CN109108238 B CN 109108238B CN 201811103803 A CN201811103803 A CN 201811103803A CN 109108238 B CN109108238 B CN 109108238B
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周国华
袁秋红
皮晓明
陈倪莉
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Abstract

一种高电阻率铁基纳米晶合金薄带制备方法，按Fe73.5Cu1Nb3Si13.5B9配方称重，加入真空感应炉熔炼，加料顺序为先将纯铁、铌铁放进熔炼炉中，完全熔化后再加入硼铁和电解铜，完全熔化；在所得熔体中加入SiO2陶瓷粉末及硅，熔炼，形成陶瓷粉末掺杂铁基纳米晶母合金钢锭；再放入中频感应熔炼炉中二次重熔，将钢液倒入预热压力喷嘴包中；钢液体温度稳定后，喷至高速旋转的铜辊，即可得到陶瓷粉末掺杂的高电阻率铁基纳米晶合金薄带。本发明制备的铁基纳米晶合金薄带具有高电阻率、低损耗、高Bs值、高磁导率等优异的综合软磁性能。

Description

一种高电阻率铁基纳米晶合金薄带制备方法
技术领域
本发明属于软磁合金材料制备领域，涉及一种铁基纳米晶合金薄带制备方法。
背景技术
铁基纳米晶合金软磁材料具有高Bs、高磁导率、低矫顽力等优异的软磁性能，并且是成本低廉的铁基材料，被广泛应用于计算机、通讯等开关电源、汽车电子、家用电器、电力与工业自动化控制、精密测量（计量）、新能源等领域。随着开关电源高频化的不断发展，对软磁材料的应用频率提出了更高的要求。由于铁基纳米晶合金是一种金属材料，其电阻率较低，如国标牌号1K107材质（合金成份为Fe73.5Cu1Nb3Si13.5B9）电阻率仅约为90uΩ/cm。低电阻率使其最佳应用频率范围为10KHz-100KHz，难以满时代发展的需求。目前，一般是通过减小纳米晶合金带材的厚度以减小其涡流损耗，从而提高其高频性能。由于带材厚度不可能无限制的减小，纳米晶合金高频磁性能的提高有限，无法满足市场对磁材高频性能的需求。在200KHz以上的高频应用领域，目前只能选高电阻率的铁氧体软磁材料。与铁基纳米晶合金相比，铁氧体软磁材料Bs值低、磁导率低等综合磁性能差，很难满足开关电源高功率密度化的需求。而高电阻率铁基纳米晶合金薄带，具有高电阻率、低损耗、高Bs值、高磁导率等特点，必将成为高频应用领域理想的软磁材料。通常，陶瓷相，如SiO2具有较高的电阻率。因此，在铁基合金中添加陶瓷相，可有效调控铁基纳米晶带材的电阻率，将有望获得具有高电阻率的铁基纳米晶磁材，以满足市场需求。
发明内容
本发明是针对上述现有技术存在的问题，提供一种高电阻率铁基纳米晶合金薄带制备方法，在1K107合金成份的基础通过在炼钢制备母合金过程中添加陶瓷粉末，经二次重熔后利用单辊熔体急冷法制备出陶瓷粉末掺杂的铁基纳米晶合金薄带。具有高电阻率、低损耗、高Bs值、高磁导率等特点，具有优异的高频软磁性能。
本发明是通过以下技术方案实现的。
本发明所述的一种高电阻率铁基纳米晶合金薄带制备方法，包括以下步骤。
（1）按照Fe73.5Cu1Nb3Si13.5B9配方经换算成重量比后进行称重配料，把按比例配好的原材料加入真空感应炉熔炼，Nb、B分别采用铌铁、硼铁中间合金，加料顺序为先将纯铁、铌铁放进熔炼炉中，加热至完全熔化后再加入硼铁和电解铜，待硼铁、电解铜也完全熔化后得到熔化好的熔体。
（2）按0.1-0.5%的质量比，在步骤（1）所得熔体中加入600-800目的SiO2 陶瓷粉末，然后再加入硅。将熔炼温度调至1500-1600℃，冶炼100-120min后，倒入冷却铸盘，形成陶瓷粉末掺杂铁基纳米晶母合金钢锭。
（3）将冶炼好的陶瓷粉末掺杂铁基纳米晶母合金钢锭放入中频感应熔炼炉中进行二次重熔，温度1200-1350℃，熔炼60-80min后，将钢液倒入预热保温1250℃的中间压力喷嘴包中。
（4）待中间压力喷嘴包中钢液体温度稳定后，钢液在氩气恒压力作用从底部的喷嘴喷至高速旋转的铜辊，以106℃/S超急冷，铜辊线速度控制在25-35m/s、通过控制喷嘴与铜辊之间0.6-0.8mm缝隙的距离喷出带材。即可得到陶瓷粉末掺杂的高电阻率铁基纳米晶合金薄带。
本发明采用上述步骤方法，完成了陶瓷粉末掺杂的高电阻率铁基纳米晶合金薄带的制备工艺过程。陶瓷粉末的加入，作为非金属材料可大幅度提高铁基纳米晶合金的电阻率。同时，又可以起到阻碍晶粒长大的作用。使制备的铁基纳米晶合金薄带具有高电阻率、低损耗、高Bs值、高磁导率等优异的综合软磁性能。
具体实施方式
本发明将通过以下实施例作进一步说明。
实施例1。
按Fe73.5Cu1Nb3Si13.5B9配方经换算成重量比后进行称重配制原材料20kg，Nb、B分别采用铌铁、硼铁中间合金。将原材料加入真空感应炉熔炼，加料顺序为先将纯铁、铌铁放进熔炼炉中，加热至完全熔化后再加入硼铁和电解铜，待硼铁、电解铜也完全熔化后再加入质量为0.1%，粒度为800目的SiO2陶瓷粉末，然后再加入硅。设定熔炼的温度1550℃，冶炼100min后，倒入冷却铸盘，形成陶瓷粉末掺杂铁基纳米晶母合金钢锭。
将冶炼好的陶瓷粉末掺杂铁基纳米晶母合金钢锭放入中频感应熔炼炉，二次重熔，温度1300℃，熔炼80min后，将钢液倒入预热保温1250℃的中间压力喷嘴包中。待中间压力喷嘴包中钢液体温度稳定后，钢液在氩气恒压力作用从底部的喷嘴喷至高速旋转的铜辊，以25m/s线速度、通过控制喷嘴与铜辊之间缝隙的距离为0.8mm喷出带材。
所喷制带材，宽度为15mm，厚度为22-24μm，绕制成40×32×15mm尺寸的环形磁芯，经退火热处理后测试Bs=1.08T，Hc=15.6A/m，电阻率ρ=560uΩ/cm，100KHz磁导率：25000～26000，具有优异的高频磁性能。
实施例2。
按Fe73.5Cu1Nb3Si13.5B9配方经换算成重量比后进行称重配制原材料20kg，Nb、B分别采用铌铁、硼铁中间合金。将原材料加入真空感应炉熔炼，加料顺序为先将纯铁、铌铁放进熔炼炉中，加热至完全熔化后再加入硼铁和电解铜，待硼铁、电解铜也完全熔化后，加入质量为0.3%，粒度为600目的SiO2陶瓷粉末，然后再加入硅。设定熔炼的温度1550℃，冶炼100min后，倒入冷却铸盘，形成陶瓷粉末掺杂铁基纳米晶母合金钢锭。
将冶炼好的陶瓷粉末掺杂铁基纳米晶母合金钢锭放入中频感应熔炼炉，二次重熔，温度1300℃，熔炼80min后，将钢液倒入预热保温1250℃的中间压力喷嘴包中。待中间压力喷嘴包中钢液体温度稳定后，钢液在氩气恒压力作用从底部的喷嘴喷至高速旋转的铜辊，以25m/s线速度、通过控制喷嘴与铜辊之间缝隙的距离为0.8mm喷出带材。
所喷制带材，宽度为15mm，厚度为26-28μm，绕制成40×32×15mm尺寸的环形磁芯，经退火热处理后测试Bs=1.0T，Hc=25.2A/m，电阻率ρ=870uΩ/cm，100KHz磁导率：25000～26000，具有优异的高频磁性能。

Claims (1)

1.一种高电阻率铁基纳米晶合金薄带制备方法，其特征是包括以下步骤：
（1）按照Fe73.5Cu1Nb3Si13.5B9配方经换算成重量比后进行称重配料，把按比例配好的原材料加入真空感应炉熔炼，Nb、B分别采用铌铁、硼铁中间合金，加料顺序为先将纯铁、铌铁放进熔炼炉中，加热至完全熔化后再加入硼铁和电解铜，待硼铁、电解铜也完全熔化后得到熔化好的熔体；
（2）按0.1-0.5%的质量比，在步骤（1）所得熔体中加入600-800目的SiO2 陶瓷粉末，然后再加入硅；将熔炼温度调至1500-1600℃，冶炼100-120min后，倒入冷却铸盘，形成陶瓷粉末掺杂铁基纳米晶母合金钢锭；
（3）将冶炼好的陶瓷粉末掺杂铁基纳米晶母合金钢锭放入中频感应熔炼炉中进行二次重熔，温度1200-1350℃，熔炼60-80min后，将钢液倒入预热保温1250℃的中间压力喷嘴包中；
（4）待中间压力喷嘴包中钢液体温度稳定后，钢液在氩气恒压力作用从底部的喷嘴喷至高速旋转的铜辊，以106℃/S超急冷，铜辊线速度控制在25-35m/s、通过控制喷嘴与铜辊之间0.6-0.8mm缝隙的距离喷出带材；即可得到陶瓷粉末掺杂的高电阻率铁基纳米晶合金薄带。
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