CN110808138A - Amorphous mixed powder, finished powder, magnetic powder core and preparation method thereof - Google Patents
Amorphous mixed powder, finished powder, magnetic powder core and preparation method thereof Download PDFInfo
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/147—Alloys characterised by their composition
- H01F1/153—Amorphous metallic alloys, e.g. glassy metals
- H01F1/15308—Amorphous metallic alloys, e.g. glassy metals based on Fe/Ni
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/147—Alloys characterised by their composition
- H01F1/153—Amorphous metallic alloys, e.g. glassy metals
- H01F1/15358—Making agglomerates therefrom, e.g. by pressing
- H01F1/15366—Making agglomerates therefrom, e.g. by pressing using a binder
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
- H01F41/0266—Moulding; Pressing
Abstract
The invention provides amorphous mixed powder, which comprises flaky first amorphous powder and spherical second amorphous powder, wherein the first amorphous powder and the second amorphous powder are uniformly mixed; the alloy component of the first amorphous powder and/or the second amorphous powder comprises Fe(100‑x‑y‑z‑a‑b)SixByCzMaNbWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5; the amorphous mixed powder can be used for preparing corresponding finished product powder and magnetic powder cores; the amorphous mixed powder, the finished powder and the magnetic powder core are optimized through the design of alloy components, have the beneficial technical effect of excellent comprehensive magnetic performance, and meet the application requirement of amorphous elements with high performance requirements.
Description
Technical Field
The invention relates to the technical field of soft magnetic alloy metallurgy, in particular to amorphous mixed powder, finished powder, a magnetic powder core and a preparation method thereof.
Background
The amorphous material has high saturation magnetic induction, high magnetic conductivity, low coercive force, low high-frequency loss, good strong hardness, wear resistance, corrosion resistance, good temperature and environmental stability and the like, has excellent comprehensive performance, replaces permalloy, silicon steel and ferrite, is applied to power electronic technology, shows the characteristics of small volume, high efficiency, energy conservation and the like, and has the optimal cost performance ratio in all metal soft magnetic materials.
In the amorphous alloy applied in the prior art, like the conventional 1K101 Fe-Si-B ternary amorphous alloy, the corresponding amorphous element prepared from the amorphous alloy has a series of defects of low magnetic permeability, large coercive force, high loss and the like.
Disclosure of Invention
The invention provides iron-based amorphous mixed powder, finished powder, a magnetic powder core and a preparation method thereof to overcome the defects of the prior art.
The amorphous mixed powder comprises flaky first amorphous powder and spherical second amorphous powder, and the first amorphous powder and the second amorphous powder are uniformly mixed; the alloy component of the first amorphous powder and/or the second amorphous powder comprises Fe(100-x-y-z-a-b)SixByCzMaNbWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5.
Further, the amorphous mixed powder contains Fe76Si7.5B7C4Ni1.5Cr3Or Fe75Si8B7C4Mo1Cr5Or Fe78Si6B8C3Ni3Mn2Or Fe76Si9B7C5Cr3Or Fe78Si6B9C4Cr3。
Further, the powder ratio of the first amorphous powder is as follows: 10-30% of-100 meshes to +150 meshes, 20-50% of-150 meshes to +200 meshes, and 10-30% of-200 meshes to +270 meshes; the proportion of the second amorphous powder is 10-40%.
The amorphous finished product powder comprises the amorphous mixed powder, and the surface of the amorphous mixed powder is coated with an insulating coating layer.
The amorphous magnetic powder core contains the amorphous finished product powder.
The preparation method of the amorphous mixed powder comprises the following steps:
s1, smelting and preparing the master alloy, wherein the component expression of the master alloy obtained by smelting is Fe(100-x-y-z-a-b)SixByCzMaNbWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5;
s2, preparing first amorphous powder in a flake shape and second amorphous powder in a sphere-like shape from the master alloy;
and S3, proportionally mixing the first amorphous powder and the second amorphous powder to obtain the amorphous mixed powder.
The preparation method of the amorphous finished product powder comprises the following steps:
s1, smelting and preparing the master alloy, wherein the component expression of the master alloy obtained by smelting is Fe(100-x-y-z-a-b)SixByCzMaNbWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5;
s2, preparing first amorphous powder in a flake shape and second amorphous powder in a sphere-like shape from the master alloy;
s3, proportionally mixing the first amorphous powder and the second amorphous powder to obtain amorphous mixed powder;
s4, carrying out insulation coating treatment on the amorphous mixed powder to obtain amorphous coated powder;
and S5, adding a lubricant into the amorphous coated powder, and stirring and mixing to obtain amorphous finished powder.
The preparation method of the amorphous magnetic powder core comprises the following steps:
s1, smelting and preparing the master alloy, wherein the component expression of the master alloy obtained by smelting is Fe(100-x-y-z-a-b)SixByCzMaNbWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5;
s2, preparing first amorphous powder in a flake shape and second amorphous powder in a sphere-like shape from the master alloy;
s3, proportionally mixing the first amorphous powder and the second amorphous powder to obtain amorphous mixed powder;
s4, carrying out insulation coating treatment on the amorphous mixed powder to obtain amorphous coated powder;
s5, adding a lubricant into the amorphous coated powder, and stirring and mixing to obtain amorphous finished powder;
s6, performing pressing treatment, sintering treatment, annealing treatment and curing treatment on the amorphous finished product powder to obtain a magnetic powder core base block;
and S7, performing surface coating treatment on the magnetic powder core base block to obtain the amorphous magnetic powder core.
Further, a first insulation coating method, a second insulation coating method or a third insulation coating method is applied to perform insulation coating treatment on the amorphous mixed powder;
the first insulation cladding method comprises the following steps:
s4-01, mixing and attaching inorganic powder to the amorphous mixed powder by ultrasonic waves to obtain amorphous attached powder;
and S4-02, mixing and fully reacting the alkali solution with the amorphous adhesive powder, drying and fixing by using a binder to fix the surface of the amorphous adhesive powder to form an insulating coating layer, thus obtaining the amorphous coated powder.
The second insulation covering method comprises the following steps:
s4-11, preheating and heating a rotary furnace to 240-450 ℃, and adding the amorphous mixed powder into the rotary furnace;
and S4-12, continuously introducing oxygen-containing air into the rotary furnace, turning the amorphous mixed powder in the rotary furnace, and fully reacting the surface of the amorphous mixed powder with the oxygen-containing air to form an insulating coating layer on the surface of the amorphous mixed powder, so as to obtain the amorphous coated powder.
The third insulation covering method includes the steps of:
and S4-21, adding the amorphous mixed powder by using a cohesive inorganic substance, and uniformly mixing to fix the surface of the amorphous mixed powder to form an insulating coating layer so as to obtain the amorphous coated powder.
Further, in step S7, the method includes the following steps:
s7-1, performing surface pretreatment on the magnetic powder core base block to form a pretreatment insulating layer on the surface of the magnetic powder core base block;
s7-2, carrying out preheating treatment on the magnetic powder core base block after surface pretreatment, wherein the preheating treatment temperature is 180-240 ℃; then, performing roller coating treatment by using a second insulating material; and adsorbing and melting the second insulating material by self heat of the preheated magnetic powder core base block so as to form a roll coating on the pretreated insulating layer.
Further, in step S7-1, the method includes the following steps:
s7-1-01, heating the magnetic powder core base block to a temperature of 150-250 ℃;
s7-1-02, performing electrostatic spraying treatment on the magnetic powder core base block heated and heated by the first insulating powder to form the pre-treatment insulating layer on the surface of the magnetic powder core base block; the first insulating powder is acetal insulating powder, phenolic insulating powder or epoxy insulating powder.
Further, in step S7-1, the method includes the following steps:
s7-1-11, performing spraying treatment on the magnetic powder core base block by using first insulating paint; the first insulating paint is acetal insulating paint or phenolic insulating paint or epoxy insulating paint;
s7-1-21, baking and heating the magnetic powder core base block after spraying treatment, wherein the baking and heating temperature is 100-150 ℃; so that the surface of the magnetic powder core base block is formed with the pretreatment insulating layer.
The invention has the beneficial effects that:
the amorphous mixed powder, the finished powder and the magnetic powder core are optimized through the design of alloy components, have the beneficial technical effect of excellent comprehensive magnetic performance, and meet the application requirement of amorphous elements with high performance requirements.
Detailed Description
In order to make the technical solution, objects and advantages of the present invention more apparent, the following examples further illustrate the present invention.
The invention relates to a preparation method of an amorphous magnetic powder core, which specifically comprises the following steps:
s1, smelting the alloy raw materials in a smelting furnace to prepare a master alloy;
s2, preparing corresponding amorphous powder from the master alloy;
s3, mixing the amorphous powder according to a ratio to obtain amorphous mixed powder;
s4, carrying out insulation coating treatment on the amorphous mixed powder to obtain amorphous coated powder;
s5, adding a lubricant into the amorphous coated powder, and stirring and mixing to obtain amorphous finished powder;
s6, performing pressing treatment, sintering treatment, annealing treatment and curing treatment on the amorphous finished product powder to obtain a magnetic powder core base block;
and S7, performing surface coating treatment on the magnetic powder core base block to obtain the amorphous magnetic powder core.
In step S1, the present invention provides a mother alloy for Fe-based amorphous alloy, which comprisesThe composition expression is Fe(100-x-y-z-a-b)SixByCzMaNbWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5.
The mother alloy for the iron-based amorphous alloy may be based on Fe78Si9B13The preparation is carried out by adding elements to change the internal atomic arrangement of the amorphous alloy.
Specifically, the Fe is added to the mixture according to the preparation requirement78Si9B13On the basis of the components of the alloy, the alloy is designed by adding and replacing elements such as C, Ni, Mo, Cr, Mn and the like; calculating the weight ratio of each required element according to the designed component atomic ratio, and further calculating the weight of each raw material required by each element added; and calculating the weight of each required raw material and smelting to prepare the master alloy for the iron-based amorphous alloy.
Example 1:
the chemical composition expression of the master alloy for the iron-based amorphous alloy is Fe76Si7.5B7C4Ni1.5Cr3The corresponding amorphous powder is prepared from the master alloy, and then the corresponding magnetic powder core can be prepared after conventional powder proportioning and mixing, conventional insulating coating treatment, pressing treatment, sintering treatment, annealing treatment, curing treatment and surface coating treatment.
Specifically, the powder ratio is 100-150 meshes to 10%, 150-200 meshes to 50%, 200-270 meshes to 30%, and 270-400 meshes to 10%, the magnetic powder core prepared by the method has the magnetic permeability of 60, the direct current magnetic biasing capacity of 55%, the loss of 310mw/cm3@50k, and 100 mT.
Example 2:
the chemical composition expression of the master alloy for the iron-based amorphous alloy is Fe75Si8B7C4Mo1Cr5The corresponding amorphous powder is prepared from the master alloy, and the corresponding amorphous powder is mixed according to the conventional powder proportion, so that the amorphous powder is often mixedAfter regular insulating coating treatment, pressing treatment, sintering treatment, annealing treatment, curing treatment and surface coating treatment, the corresponding magnetic powder core can be prepared.
Specifically, the powder ratio is 100-150 meshes to 10%, 150-200 meshes to 50%, 200-270 meshes to 30%, 270-400 meshes to 10%, the magnetic powder core prepared by the method has the magnetic conductivity of 60 and the direct current magnetic biasing capacity of 51%; the loss is 186mw/cm3@50k,100 mT.
Example 3:
the chemical composition expression of the master alloy for the iron-based amorphous alloy is Fe78Si6B8C3Ni3Mn2The corresponding amorphous powder is prepared from the master alloy, and then the corresponding magnetic powder core can be prepared after conventional powder proportioning and mixing, conventional insulating coating treatment, pressing treatment, sintering treatment, annealing treatment, curing treatment and surface coating treatment.
Specifically, the powder ratio is 100-150 meshes to 10%, 150-200 meshes to 50%, 200-270 meshes to 30%, 270-400 meshes to 10%, the magnetic powder core prepared by the method has the magnetic conductivity of 60 and the direct current magnetic biasing capacity of 64%; the loss was 362mw/cm3@50k,100 mT.
Example 4:
the chemical composition expression of the master alloy for the iron-based amorphous alloy is Fe76Si9B7C5Cr3The corresponding amorphous powder is prepared from the master alloy, and then the corresponding magnetic powder core can be prepared after conventional powder proportioning and mixing, conventional insulating coating treatment, pressing treatment, sintering treatment, annealing treatment, curing treatment and surface coating treatment.
Specifically, the powder ratio is 100-150 meshes to 10%, 150-200 meshes to 50%, 200-270 meshes to 30%, and 270-400 meshes to 10%, the magnetic powder core prepared by the method has the magnetic permeability of 60, the direct current magnetic biasing capacity of 54%, the loss of 280mw/cm3@50k, and 100 mT.
Example 5:
the chemical composition expression of the master alloy for the iron-based amorphous alloy is Fe78Si6B9C4Cr3The corresponding amorphous powder is prepared from the master alloy, and then the corresponding magnetic powder core can be prepared after conventional powder proportioning and mixing, conventional insulating coating treatment, pressing treatment, sintering treatment, annealing treatment, curing treatment and surface coating treatment.
Specifically, the powder ratio is 100-150 meshes to 10%, 150-200 meshes to 50%, 200-270 meshes to 30%, and 270-400 meshes to 10%, and the magnetic powder core prepared by the method has the magnetic conductivity of 60, the direct current magnetic biasing capacity of 56%, the loss of 275mw/cm3@50k, and 100 mT.
Conventionally, the performance of the amorphous alloy is usually embodied by the performance of the amorphous strip, and the corresponding amorphous strip prepared by the corresponding iron-based amorphous alloy master alloy is embodied as follows:
| alloy composition | Bs(T) | Hc(A/m) | μi@1k,0.5V |
| Fe76Si7.5B7C4Ni1.5Cr3 | 1.54 | 1.7 | 21400 |
| Fe75Si8B7C4Mo1Cr5 | 1.33 | 1.2 | 38600 |
| Fe78Si6B8C3Ni3Mn2 | 1.71 | 3.6 | 8400 |
| Fe76Si9B7C5Cr3 | 1.42 | 1.5 | 28500 |
| Fe78Si6B9C4Cr3 | 1.51 | 2.2 | 13600 |
Example 6:
in step S2, the master alloy is further rapidly cooled to perform the corresponding amorphous powder preparation, wherein the rapid cooling method can be selected from the group consisting of: the rapid cooling amorphous preparation method in the prior art comprises a single-roller rapid quenching method, a double-roller rapid quenching method, a water atomization method, an air atomization method, a water-air atomization combination method and the like.
By the single-roller rapid quenching method or the double-roller rapid quenching method, the mother alloy can be prepared into corresponding amorphous strips, and the prepared amorphous strips are mechanically crushed to prepare corresponding flaky first amorphous powder.
By means of the water atomization method, the gas atomization method, the water-gas atomization combination method and the like, the second amorphous powder with the corresponding similar spherical shape can be prepared from the master alloy.
In the step S2, it includes the following steps:
s2-1, preparing first amorphous powder in a flaky state by using the mother alloy for the iron-based amorphous alloy;
s2-2, preparing a second amorphous powder in a spheroidal state by using the mother alloy for the iron-based amorphous alloy.
In step S3, the present invention mixes the first amorphous powder and the second amorphous powder to obtain an amorphous mixed powder, and the mixing method of the amorphous mixed powder is selected as follows:
the mesh range of the first amorphous powder is-100 to +270 meshes, and the mesh range of the second amorphous powder is-200 to +400 meshes. 10-30% of-100 meshes to +150 meshes, 20-50% of-150 meshes to +200 meshes, and 10-30% of-200 meshes to +270 meshes; the proportion of the second amorphous powder is 10-40%. The amorphous mixed powder with good flowability is obtained by adjusting the proportion of the first amorphous powder and the second amorphous powder which are arranged in different mesh numbers, and the main parameters of good powder flowability are as follows: bulk density, tap density, angle of repose, degree of dispersion, etc.; the comprehensive index is a fluidity index which can be tested by using a Dandongbaote powder characteristic analyzer; the fluidity index is above 70 and is a good grade, and the larger the fluidity index is, the better the fluidity is; the powder with good fluidity has smaller resistance among powder particles in the molding process, thereby being beneficial to molding; under the same pressure condition, the magnetic powder core prepared by the method has higher density and better product performance.
The first amorphous powder and the second amorphous powder with different types of appearances are mixed and applied, so that the flowability and the forming density of the powder are effectively improved, and the direct current bias capability of the amorphous magnetic powder core prepared by applying the amorphous magnetic powder core is further improved.
The prepared product has the following properties by adopting the same production conditions: the prepared improved magnetic powder core product has higher magnetic conductivity and lower loss, and is more favorable for the requirements of miniaturization and high-frequency application of the product.
Example 7:
in step S4, a first insulation coating method is applied to perform insulation coating processing on the amorphous mixed powder, the first insulation coating method including the steps of:
s4-01, mixing and attaching inorganic powder to the amorphous mixed powder by ultrasonic waves to obtain amorphous attached powder;
and S4-02, mixing and fully reacting the alkali solution with the amorphous adhesive powder, drying and fixing by using a binder to fix the surface of the amorphous adhesive powder to form an insulating coating layer, thus obtaining the amorphous coated powder.
The inorganic powder is SiO2Or Fe2O3And the like inorganic oxides; the mesh number of the inorganic powder is more than 8000 meshes, so that the ultrafine effect is achieved, and the particles of the inorganic powder approach to the nano level.
Specifically, the amorphous mixed powder of each mesh is mixed and uniformly mixed by a V-shaped mixer, and the V-shaped mixer is used for outputting ultrasonic waves by an ultrasonic vibrator during the mixing and stirring process of the amorphous mixed powder, so that the ultrafine inorganic powder has a certain adsorption capacity to uniformly adhere the inorganic powder to the amorphous mixed powder, thereby obtaining the amorphous adhered powder.
Mixing an alkali solution with the amorphous attached powder and fully reacting, wherein the alkali solution can be selected from a NaOH solution, and the reaction process comprises the following steps: SiO 22+2NaOH＝Na2SiO3+H2O, stirring uniformly and fully reacting under the condition of normal temperature; adding a binder into the amorphous attaching powder which is fully reacted with the alkali solution to stir until the amorphous attaching powder is uniformly dried, so that the surface of the amorphous attaching powder is provided with Na2SiO3To obtain an amorphous coated powder.
The binder is a cohesive inorganic or organic binder; the adhesive is silicon resin, water glass or epoxy resin, and the addition amount of the adhesive is 0.2-2.5%.
The addition amount of the inorganic powder can be increased according to the performance requirement according to the content required by forming a single-layer insulating coating layer; the thickness of the attached insulating coating layer approaches to a single layer and approaches to complete attachment.
The first insulation coating method is applied by adopting a non-corrosive treatment method to carry out corresponding insulation coating application so as to effectively improve the problems of cost and environmental pollution, does not need acid solution to carry out corresponding corrosive reaction, can effectively avoid the change of the amorphous structure on the surface of the powder particles caused by nonuniform coating and excessive local heat release of the powder particles, and avoids the phenomena of magnetic permeability reduction and other magnetic property deterioration of amorphous finished powder.
The prepared product has the following properties by adopting the same production conditions: the prepared improved magnetic powder core product has higher magnetic conductivity and lower loss, and is more favorable for the requirements of miniaturization and high-frequency application of the product.
Example 8:
preparing a master alloy for the Fe-based amorphous alloy containing Fe and Si based on the first and/or second amorphous powder; in step S4, a second insulation coating method is applied to perform insulation coating treatment, the second insulation coating method includes the following steps:
s4-11, preheating and heating a rotary furnace to 240-450 ℃, and adding the amorphous mixed powder into the rotary furnace;
and S4-12, continuously introducing oxygen-containing air into the rotary furnace, turning the amorphous mixed powder in the rotary furnace, and fully reacting the surface of the amorphous mixed powder with the oxygen-containing air to form an insulating coating layer on the surface of the amorphous mixed powder, so as to obtain the amorphous coated powder.
Specifically, the obtained amorphous mixed powder is subjected to a baking treatment in a rotary kiln to stress-relieve annealing(ii) a The rotary furnace is provided with a corresponding oxygen introducing mechanism and a corresponding turnover mechanism, oxygen-containing air is continuously introduced into the rotary furnace through the oxygen introducing mechanism, the amorphous mixed powder in the furnace is turned over through the turnover mechanism, the surface of the amorphous mixed powder is fully reacted with the oxygen-containing air, and the chemical reaction formula of the amorphous mixed powder relates to the formula; fe + O2＝Fe2O3And Si + O2＝SiO2Turning and stirring evenly for full reaction; so that an insulating coating layer with corresponding oxide is formed on the surface of the amorphous mixed powder to obtain coated powder.
According to the second insulation coating method, the insulation coating layer is generated in the insulation coating step by adopting hot air, so that the problems of production cost and environmental pollution are effectively solved; meanwhile, the quality of the insulating coating layer can be effectively improved; the influence of foreign substances introduced in the insulating and coating process on the magnetic performance of the prepared amorphous magnetic powder core is reduced.
The prepared product has the following properties by adopting the same production conditions: the prepared improved magnetic powder core product has higher magnetic conductivity and lower loss, and is more favorable for the requirements of miniaturization and high-frequency application of the product.
Example 9:
in step S4, a third insulation coating method is applied to perform the insulation coating process, the third insulation coating method includes the following steps:
and S4-21, adding the amorphous mixed powder by using a cohesive inorganic substance, and uniformly mixing to fix the surface of the amorphous mixed powder to form an insulating coating layer so as to obtain the amorphous coated powder.
Adding the obtained amorphous mixed powder into a double-shaft stirrer, and adding a cohesive inorganic substance to stir until the mixture is uniform, so that an insulating coating layer is formed on the surface of the amorphous mixed powder, and amorphous coated powder is obtained; the adopted cohesive inorganic matter is a sodium silicate solution or inorganic silicon resin, preferably the sodium silicate solution, the modulus of the sodium silicate solution is preferably 2.5-3.5, the Baume degree is preferably 0.35-0.48, the ratio of the sodium silicate solution is 0.5-3.2%, the sodium silicate solution is diluted by a diluent, the ratio of the diluent is 1.2-6.5%, and the diluent can be selected from water, acetone and ethanol.
According to the third insulation coating method, the amorphous mixed powder is coated by the cohesive inorganic substance, and the amorphous mixed powder is used as the adhesive and the insulation coating agent, so that the production efficiency is effectively improved, the introduction of non-magnetic substances is reduced, the magnetic conductivity of the product is improved, and the magnetic performance of the product is optimized.
In step S5, the lubricant used in the above embodiments includes, but is not limited to, zinc stearate, paraffin wax, and barium stearate.
The prepared product has the following properties by adopting the same production conditions: the prepared improved magnetic powder core product has higher magnetic conductivity and lower loss, and is more favorable for the requirements of miniaturization and high-frequency application of the product.
Example 10:
in the invention, a surface coating treatment method of an amorphous product is applied, which comprises the following steps:
(1) carrying out surface pretreatment on the amorphous product to form a pretreatment insulating layer on the surface of the amorphous product;
(2) carrying out preheating treatment on the amorphous product subjected to surface pretreatment, wherein the preheating treatment temperature is 180-240 ℃; then, performing roller coating treatment by using a second insulating material; and adsorbing and melting the second insulating material by the preheated amorphous product with self heat so as to form a roll coating on the pretreated insulating layer.
The second insulating material is acetal insulating powder, phenolic insulating powder or epoxy insulating powder.
The thickness range of the pre-treatment insulating layer is 20-150 mu m, and preferably 30-80 mu m; the thickness range of the roller coating is 100-400 mu m, and preferably 150-250 mu m.
Wherein, in the step (1), the method comprises the following steps:
(1-01) heating the amorphous product to raise the temperature, wherein the heating temperature is 150-250 ℃;
(1-02) performing electrostatic spraying treatment on the heated and heated amorphous product by using first insulating powder through electrostatic spraying equipment to form a pretreated insulating layer on the surface of the amorphous product; the first insulating powder is acetal insulating powder, phenolic insulating powder or epoxy insulating powder.
Example 11:
the present embodiment is different from the above embodiment 10 in that, in the step (1), it includes the following steps:
(1-11) spraying the amorphous product with a first insulating varnish by using a liquid spray gun; the first insulating paint is acetal insulating paint or phenolic insulating paint or epoxy insulating paint;
(1-21) baking and heating the sprayed amorphous product, wherein the baking and heating temperature is 100-150 ℃; so that the surface of the amorphous product is formed with the pretreatment insulating layer.
Specifically, the application principle of the amorphous product surface coating treatment method is as follows:
firstly, performing surface pretreatment on the amorphous product by using first insulating powder or first insulating paint to prepare a thin insulating pretreatment insulating layer on the surface of a rough amorphous product, so that the insulating property of the amorphous product is improved and the surface defects (such as residual holes) of the amorphous product are compensated to a certain extent; and then the amorphous product is subjected to roller coating treatment by using a second insulating material. Based on the premise that the amorphous product is preheated, the second insulating material in the material box can be adsorbed by the heated amorphous product in a roll coating mode to form a roll coating.
In the roll coating process, the amorphous product is in a rolling state in the material box, and the rolling speed of the amorphous product is controlled through the parameter and process adjustment of roll coating equipment, so that the uniformity of the roll coating formed by the amorphous product can be effectively controlled; the second insulating materials are intensively placed in a material box, so that the second insulating materials in the roll coating process are intensively arranged without scattering, the roll coating process basically does not consume the second insulating materials additionally, and raw materials are saved.
Compared with the prior art that the insulating coating on the surface of the amorphous product is processed by directly applying a spraying mode or directly applying a rolling coating mode, the scheme is based on the step-by-step processing application of the double-layer insulating coating, and the thickness and the uniformity of the insulating coating are controlled by adjusting the matching of the parameters of the rolling coating equipment, and the surface quality of the insulating coating is improved.
Based on the application of the amorphous product surface coating treatment method, the spraying qualification rate of the amorphous product is effectively improved, and the surface quality of the insulating coating of the amorphous product is improved; meanwhile, the uniformity of the thickness of the insulating coating can be ensured, and the coating material is saved.
Then, in step S7, the surface coating treatment method for the amorphous product described above can be applied to perform the surface coating treatment on the magnetic powder core substrate.
Example 12:
based on the application of the prior art, the mother alloy for the iron-based amorphous alloy can also be processed and prepared into a corresponding magnetic core, and the processing steps are as follows:
【1】 Preparing a corresponding amorphous strip from the master alloy for the iron-based amorphous alloy;
【2】 Winding or superposing the amorphous strip, and annealing to obtain a magnetic core matrix;
【3】 And carrying out surface coating treatment on the magnetic core substrate.
Example 13:
the magnetic core substrate prepared by the step [ 2 ] of example 12 may be subjected to a surface coating treatment by the surface coating treatment method of the amorphous product described in the above example 10 or 11.
The above description is only a preferred embodiment of the present invention, and those skilled in the art may still modify the described embodiment without departing from the implementation principle of the present invention, and the corresponding modifications should also be regarded as the protection scope of the present invention.
Claims (10)
1. The amorphous mixed powder is characterized by comprising a first amorphous powder in a sheet shape and a second amorphous powder in a sphere-like shape, wherein the first amorphous powder and the second amorphous powder are uniformly mixed; the alloy component of the first amorphous powder and/or the second amorphous powder comprises Fe(100-x-y-z-a-b)SixByCzMaNbWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5.
2. The amorphous mixed powder according to claim 1, wherein the composition of the amorphous mixed powder comprises Fe76Si7.5B7C4Ni1.5Cr3Or Fe75Si8B7C4Mo1Cr5Or Fe78Si6B8C3Ni3Mn2Or Fe76Si9B7C5Cr3Or Fe78Si6B9C4Cr3。
3. The amorphous mixed powder according to claim 1, wherein the powder ratio of the first amorphous powder is: 10-30% of-100 meshes to +150 meshes, 20-50% of-150 meshes to +200 meshes, and 10-30% of-200 meshes to +270 meshes; the proportion of the second amorphous powder is 10-40%.
4. Amorphous finished powder, comprising the amorphous mixed powder as claimed in any one of claims 1 to 3, wherein the surface of the amorphous mixed powder is coated with an insulating coating layer.
5. An amorphous magnetic powder core comprising the amorphous final powder according to claim 4.
6. The method for preparing amorphous mixed powder as claimed in any one of claims 1 to 3, comprising the steps of:
s1, smelting and preparing the master alloy, wherein the component expression of the master alloy obtained by smelting is Fe(100-x-y-z-a-b)SixByCzMaNbWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5;
s2, preparing first amorphous powder in a flake shape and second amorphous powder in a sphere-like shape from the master alloy;
and S3, proportionally mixing the first amorphous powder and the second amorphous powder to obtain the amorphous mixed powder.
7. The method for preparing amorphous finished powder according to claim 4, comprising the steps of:
s1, smelting and preparing the master alloy, wherein the component expression of the master alloy obtained by smelting is Fe(100-x-y-z-a-b)SixByCzMaNbWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5;
s2, preparing first amorphous powder in a flake shape and second amorphous powder in a sphere-like shape from the master alloy;
s3, proportionally mixing the first amorphous powder and the second amorphous powder to obtain amorphous mixed powder;
s4, carrying out insulation coating treatment on the amorphous mixed powder to obtain amorphous coated powder;
and S5, adding a lubricant into the amorphous coated powder, and stirring and mixing to obtain amorphous finished powder.
8. The method for preparing amorphous magnetic powder core according to claim 5, comprising the steps of:
s1, smelting and preparing the master alloy, wherein the component expression of the master alloy obtained by smelting is Fe(100-x-y-z-a-b)SixByCzMaNbWherein M is any one of Ni and Mo elements, and N is any one of Cr and Mn elements; wherein 6 < x < 11, 9 < y < 16, 1 < z < 8, 0 < a < 5, and 0 < b < 5;
s2, preparing first amorphous powder in a flake shape and second amorphous powder in a sphere-like shape from the master alloy;
s3, proportionally mixing the first amorphous powder and the second amorphous powder to obtain amorphous mixed powder;
s4, carrying out insulation coating treatment on the amorphous mixed powder to obtain amorphous coated powder;
s5, adding a lubricant into the amorphous coated powder, and stirring and mixing to obtain amorphous finished powder;
s6, performing pressing treatment, sintering treatment, annealing treatment and curing treatment on the amorphous finished product powder to obtain a magnetic powder core base block;
and S7, performing surface coating treatment on the magnetic powder core base block to obtain the amorphous magnetic powder core.
9. The manufacturing method according to claim 7 or 8, wherein in step S4, a first insulation coating method, a second insulation coating method, or a third insulation coating method is applied to perform insulation coating treatment on the amorphous mixed powder;
the first insulation cladding method comprises the following steps:
s4-01, mixing and attaching inorganic powder to the amorphous mixed powder by ultrasonic waves to obtain amorphous attached powder;
and S4-02, mixing and fully reacting the alkali solution with the amorphous adhesive powder, drying and fixing by using a binder to fix the surface of the amorphous adhesive powder to form an insulating coating layer, thus obtaining the amorphous coated powder.
The second insulation covering method comprises the following steps:
s4-11, preheating and heating a rotary furnace to 240-450 ℃, and adding the amorphous mixed powder into the rotary furnace;
and S4-12, continuously introducing oxygen-containing air into the rotary furnace, turning the amorphous mixed powder in the rotary furnace, and fully reacting the surface of the amorphous mixed powder with the oxygen-containing air to form an insulating coating layer on the surface of the amorphous mixed powder, so as to obtain the amorphous coated powder.
The third insulation covering method includes the steps of:
and S4-21, adding the amorphous mixed powder by using a cohesive inorganic substance, and uniformly mixing to fix the surface of the amorphous mixed powder to form an insulating coating layer so as to obtain the amorphous coated powder.
10. The method of claim 8, wherein step S7 includes the steps of:
s7-1, performing surface pretreatment on the magnetic powder core base block to form a pretreatment insulating layer on the surface of the magnetic powder core base block;
s7-2, carrying out preheating treatment on the magnetic powder core base block after surface pretreatment, wherein the preheating treatment temperature is 180-240 ℃; then, performing roller coating treatment by using a second insulating material; and adsorbing and melting the second insulating material by self heat of the preheated magnetic powder core base block so as to form a roll coating on the pretreated insulating layer.
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