CN111266273A - 钕铁硼系稀土永磁表面扩散源喷涂方法及磁体制造方法 - Google Patents

钕铁硼系稀土永磁表面扩散源喷涂方法及磁体制造方法 Download PDF

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CN111266273A
CN111266273A CN202010202361.XA CN202010202361A CN111266273A CN 111266273 A CN111266273 A CN 111266273A CN 202010202361 A CN202010202361 A CN 202010202361A CN 111266273 A CN111266273 A CN 111266273A
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diffusion source
spray gun
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魏中华
梅锐
许丁丁
石晓宁
付松
王黎旭
何杰杰
满超
张立新
吴小康
赵栋梁
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Zhejiang Innuovo Magnetics Industry Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
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    • B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
    • B05B13/02—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
    • B05B13/02—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work
    • B05B13/04—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation
    • B05B13/0405—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation with reciprocating or oscillating spray heads
    • B05B13/041—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation with reciprocating or oscillating spray heads with spray heads reciprocating along a straight line
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
    • B05D3/0218—Pretreatment, e.g. heating the substrate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
    • B05D3/0254—After-treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/10—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by other chemical means
    • B05D3/104—Pretreatment of other substrates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
    • 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
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    • 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
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Abstract

本发明公开了钕铁硼系稀土永磁表面扩散源喷涂方法，采用喷枪给磁体表面喷涂扩散源，所述磁体放在料盘上运动，喷枪往复运动喷涂扩散源溶液，喷枪的移动速度、料盘的移动速度和喷枪从单块磁体经过的次数满足以下关系：
Figure DDA0002419818730000011
其中l磁体为磁体长度，N为喷枪从单块磁体经过次数，V料盘为料盘移动速度，V喷枪为喷枪移动速度，且与料盘移动方向垂直，所述V料盘＝2～5cm/s，a＝0.2～0.9，b＝(1.1～3.2)*10^11，c＝450～800。钕铁硼系磁体制造方法，制作磁体毛坯，对毛坯表面进行喷砂、酸洗和研磨，对毛坯加热处理，然后按上述方法喷涂，最后进行时效处理。本发明的优点是：在喷涂时确保喷涂的一致性，在保证产品下限的同时，减少了喷涂量，同时提高磁体性能一致性，降低制造成本。

Description

钕铁硼系稀土永磁表面扩散源喷涂方法及磁体制造方法
技术领域
本发明涉及钕铁硼系稀土永磁表面扩散源喷涂方法及磁体制造方法。
背景技术
烧结钕铁硼永磁材料具有相当高的内禀矫顽力和磁能积，广泛应用于电子、电力机械、医疗器械、玩具、包装、五金机械、航天航空等领域，较常见的有永磁电机、扬声器、磁选机、计算机磁盘驱动器、磁共振成像设备仪表等。
然而烧结钕铁硼的磁稳定性较差，阻碍了高新技术领域的应用与发展。为了提升钕铁硼的综合性能，目前通过采用掺入重稀土金属镝铽来提高钕铁硼的磁性能。由于Dy2Fe14B(Tb2Fe14B)相具有较高的各向异性场以及较低磁饱和强度，所以Dy(Tb)元素的加入能较大幅度提升矫顽力，提升磁体居里温度，从而改善磁体温度稳定性，从而使得烧结钕铁硼材料可以应用于更高的温度(如：汽车电机)。
但是，重稀土在地壳中的丰度很低，储量有限，导致重稀土价格很高，使得掺入重稀土制作高性能磁体的成本大大提高。因此，寻找一种降低重稀土使用量的方法引起了企业及业内学者的重视。目前较为实用且较为成熟的一种方法就是通过晶界扩散的方式形成具有(Dy，Nu)2Fe14B((Tb，Nu)2Fe14B)壳层的Nu2Fe14B主相，这种方式使用的重稀土含量稀少，提升的矫顽力明显，而剩磁基本不变。正由于这些优点，使得晶界扩散技术得到大规模应用，目前业内较为常见扩散的方法主要有：磁控溅射、喷涂涂覆、液相沉积等。对于磁控溅射法，设备成本高昂，原材料使用的重稀土金属成本高昂，以及产能效率较低。液相沉积技术存在的沉积厚度的不可控以及液相浓度的不可控等缺点。而喷涂涂覆设备价格相对较为低廉，能实现较高产能，目前也被各大企业广泛使用，但是喷涂的均匀性问题成为了喷涂涂覆的一项技术难点。
如图1所示，曲线为喷枪在工件盘上运动的轨迹，而小方块为所要喷涂的磁体，从图中可以看到，每块磁体在喷涂过程中的状态并不一致，导致每块磁体最终喷涂的粉料含量不同。这种由于喷枪本身移动导致的喷涂不均匀问题是重喷涂法重稀土钕铁硼扩散一致性差的主要原因。
发明内容
本发明的目的在于提供钕铁硼系稀土永磁表面扩散源喷涂方法及磁体制造方法，能够有效解决现有钕铁硼系稀土永磁体性能不一致的问题。
为了解决上述技术问题，本发明是通过以下技术方案实现的：钕铁硼系稀土永磁表面扩散源喷涂方法，采用喷枪给磁体表面喷涂扩散源，所述磁体放在料盘上运动，喷枪往复运动喷涂扩散源溶液，喷枪的移动速度、料盘的移动速度和喷枪从单块磁体经过的次数满足以下关系：
Figure BDA0002419818710000021
其中l磁体为磁体长度，N为喷枪从单块磁体经过次数，V料盘为料盘移动速度，V喷枪为喷枪移动速度，且与料盘移动方向垂直，所述V料盘＝2～5cm/s，a＝0.2～0.9，b＝(1.1～3.2)*10^11，c＝450～800。
优选的，所述喷枪沿磁体长度方向往复运动喷涂扩散源溶液，降低喷枪的往返点，减少在往返点的喷涂造成涂料的浪费。
优选的，所述扩散源加入酒精或者丙醇混合，酒精或者丙醇与扩散源的混合比例为0.5-2:1，所述扩散源粒度为1～10um；在扩散源喷涂环境下，使用酒精和丙醇易于挥发，挥发后的气体无毒环保。
优选的，喷涂时的环境温度为5～60摄氏度，湿度0～50％RH，保持在此温度内可以防止溶剂在喷到产品上时挥发过早，变成干粉，影响均匀性；而在上述设定的湿度内防止吸水，造成产品氧化。
钕铁硼系磁体制造方法，包括以下步骤：
A、制作磁体毛坯，对毛坯表面进行喷砂、酸洗和研磨；
B、对经过步骤A处理后的磁体毛坯进行加热处理，加热温度60～200摄氏度，时间0.2～2小时；
C、按照权利要求1至3中任一项所述的喷涂方法，对磁体毛坯喷涂扩散源；
D、对步骤C喷涂后的磁体毛坯进行时效处理，处理温度400～600摄氏度，时效时间2～6小时。
与现有技术相比，本发明的优点是：通过磁体和料盘的参数调节喷涂工艺，在喷涂时确保喷涂的一致性，在保证产品下限的同时，减少了喷涂量，同时提高磁体性能一致性，降低制造成本。
附图说明
图1为现有喷枪运动轨迹示意图；
图2在600mm/s喷涂速度下磁体均匀性偏差值；
图3在620mm/s喷涂速度下磁体均匀性偏差值；
图4在640mm/s喷涂速度下磁体均匀性偏差值；
图5在600mm/s喷涂速度下磁体表面喷涂量分布图；
图6在620mm/s喷涂速度下磁体表面喷涂量分布图；
图7在640mm/s喷涂速度下磁体表面喷涂量分布图。
具体实施方式
下面详细描述本发明的实施例，所述实施例的示例在附图中示出。下面通过参考附图描述的实施例是示例性的，旨在用于解释本发明，而不能理解为对本发明的限制。
钕铁硼系稀土永磁表面扩散源喷涂方法，采用喷枪给磁体表面喷涂扩散源，扩散源一般选用氟化镝或氟化铽或氢化镝或氢化铽，所述磁体放在料盘上运动，喷枪往复运动喷涂扩散源溶液，喷枪的移动速度、料盘的移动速度和喷枪从单块磁体经过的次数满足以下关系：
Figure BDA0002419818710000041
其中l磁体为磁体长度，N为喷枪从单块磁体经过次数，V料盘为料盘移动速度，V喷枪为喷枪移动速度，且与料盘移动方向垂直，所述V料盘＝2～5cm/s，a＝0.2～0.9，b＝(1.1～3.2)*10^11，c＝450～800。
最好喷枪沿磁体长度方向往复运动喷涂扩散源溶液，这样可以减少折返点，从而减少在折返点上浪费的原料，而扩散源溶液，一般采用扩散源原料与酒精或者丙醇混合，酒精或者丙醇与扩散源的混合比例为0.5-2:1，使扩散源粒度为1～10um，并且最好保持不断搅拌，防止扩散源颗粒下沉。喷涂时的环境温度维持在5～60摄氏度，湿度0～50％RH，这样能防止温度过高引起溶液快速蒸发变成干粉，也能防止温度过低影响溶液的扩散，保证喷涂均匀性，同时湿度的控制防止扩散源溶液吸水氧化，而对产品均匀性产生影响。
钕铁硼系磁体制造方法，包括以下步骤：
A、制作磁体毛坯，对毛坯表面进行喷砂、酸洗和研磨；
B、对经过步骤A处理后的磁体毛坯进行加热处理，加热温度60～200摄氏度，时间0.2～2小时；
C、按照权利要求1至3中任一项所述的喷涂方法，对磁体毛坯喷涂扩散源；
D、对步骤C喷涂后的磁体毛坯进行时效处理，处理温度400～600摄氏度，时效时间2～6小时。
以下是具体举例：取自牌号为N45SH，磁体规格为34.5*11.2*1.8的钕铁硼磁体，将上述磁体通过3％HNO3酸洗，在进行喷涂前加热处理，温度200摄氏度，时间12分钟，按叠加次数为2次，用喷枪的移动速度、料盘的移动速度和喷枪从单块磁体经过的次数计算出的最优喷枪移动速度620mm/s进行喷涂，喷涂量控制在单面20mg左右，与采用600mm/s和640mm/s喷涂的磁体进行比较，由图2、图3、图4的对比可知，图2在600mm/s速度下均值偏差为32.72％，图3在620mm/s速度下均值偏差为9.61％，图4在640mm/s速度下均值偏差为36.25％，磁体的波动范围再次增加，由此说明在喷速620mm/s下，此种规格的磁体波动范围出现最优点。
图5为600mm/s的三维分布图，可以明显看到喷涂存在规律性的移动，呈现波峰波谷的波动，这正是由于磁体尺寸与喷枪速度不匹配导致的相位差而形成的周期性波动。
对照图6为620mm/s的三维分布图，可以看到波峰波谷的规律性消失了，出现的是随机性以及一些更为细小因素(如设备、粉料、气源稳定性等)造成的系统误差。由此可知数学模型的准确性。
图7为640mm/s喷速下的喷涂量分布图，波峰波谷又呈现出明显的波动。
Figure BDA0002419818710000061
Figure BDA0002419818710000062
Figure BDA0002419818710000063
Figure BDA0002419818710000071
Figure BDA0002419818710000072
表1：不同喷速下磁体磁性能上述表1中620mm/s喷速下的磁体磁性能的稳定一致性相较于600mm/s，640mm/s喷速下的有较大的提升。
以上所述仅为本发明的具体实施例，但本发明的技术特征并不局限于此，任何本领域的技术人员在本发明的领域内，所作的变化或修饰皆涵盖在本发明的专利范围之中。

Claims (5)

1.钕铁硼系稀土永磁表面扩散源喷涂方法，采用喷枪给磁体表面喷涂扩散源，其特征在于：所述磁体放在料盘上运动，喷枪往复运动喷涂扩散源溶液，喷枪的移动速度、料盘的移动速度和喷枪从单块磁体经过的次数满足以下关系：
Figure FDA0002419818700000011
其中l磁体为磁体长度，N为喷枪从单块磁体经过次数，V料盘为料盘移动速度，V喷枪为喷枪移动速度，且与料盘移动方向垂直，所述V料盘＝2～5cm/s，a＝0.2～0.9，b＝(1.1～3.2)*10^11，c＝450～800。
2.如权利要求1所述的钕铁硼系稀土永磁表面扩散源喷涂方法，其特征在于：所述喷枪沿磁体长度方向往复运动喷涂扩散源溶液。
3.如权利要求1所述的钕铁硼系稀土永磁表面扩散源喷涂方法，其特征在于：所述扩散源加入酒精或者丙醇混合，酒精或者丙醇与扩散源的混合比例为0.5-2:1，所述扩散源粒度为1～10um。
4.如权利要求1所述的钕铁硼系稀土永磁表面扩散源喷涂方法，其特征在于：喷涂时的环境温度为5～60摄氏度，湿度0～50％RH。
5.钕铁硼系磁体制造方法，其特征在于：包括以下步骤：
A、制作磁体毛坯，对毛坯表面进行喷砂、酸洗和研磨；
B、对经过步骤A处理后的磁体毛坯进行加热处理，加热温度60～200摄氏度，时间0.2～2小时；
C、按照权利要求1至3中任一项所述的喷涂方法，对磁体毛坯喷涂扩散源；
D、对步骤C喷涂后的磁体毛坯进行时效处理，处理温度400～600摄氏度，时效时间2～6小时。
CN202010202361.XA 2020-03-20 2020-03-20 钕铁硼系稀土永磁表面扩散源喷涂方法及磁体制造方法 Pending CN111266273A (zh)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114188143A (zh) * 2021-12-06 2022-03-15 湖南奔朗新材料科技有限公司 一种钕铁硼磁体的晶界扩散工艺及钕铁硼磁体制备方法

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114188143A (zh) * 2021-12-06 2022-03-15 湖南奔朗新材料科技有限公司 一种钕铁硼磁体的晶界扩散工艺及钕铁硼磁体制备方法
CN114188143B (zh) * 2021-12-06 2022-12-30 湖南奔朗新材料科技有限公司 一种钕铁硼磁体的晶界扩散工艺及钕铁硼磁体制备方法

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