CN112207283A - Preparation method of flaky ferrosilicon aluminum powder with uniform particle size, micron-sized particles with large diameter-thickness ratio and particle morphology - Google Patents
Preparation method of flaky ferrosilicon aluminum powder with uniform particle size, micron-sized particles with large diameter-thickness ratio and particle morphology Download PDFInfo
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- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
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Abstract
The invention discloses a preparation method of flaky ferrosilicon aluminum powder with uniform particle size and micron-sized large aspect ratio, belonging to the technical field of superfine metal powder preparation. The flaky ferrosilicon aluminum powder prepared by the method has high flaking rate, thickness of 1-2 mu m, uniform particle size, diameter-thickness ratio of about 30-38:1 and good soft magnetic property. According to the method, the surface of the iron-silicon-aluminum powder is softened before ball milling, so that the percent of agglomeration of the iron-silicon-aluminum powder can be improved to a great extent on the premise of ensuring the magnetic property of the iron-silicon-aluminum powder. The flaky ferrosilicon aluminum powder with large diameter-thickness ratio can further reduce air gaps inside the magnetic ring made of the flaky iron silicon aluminum powder, and meanwhile, the shape of the flaky ferrosilicon aluminum powder is favorable for reducing eddy current under high frequency, so that a finished product still has high magnetic conductivity and low loss under high frequency.
Description
Technical Field
The invention belongs to the technical field of superfine metal powder preparation, and particularly relates to a preparation method of micron-sized large-diameter-thickness-ratio flaky ferrosilicon aluminum powder with high sheet forming rate and uniform particle size.
Background
Iron-silicon-aluminum alloys, also known as Sendust alloys, were first developed in 1932 in japan. The saturated magnetostriction coefficient and the magnetocrystalline anisotropy constant of the soft magnetic alloy of Fe-9.6% Si-5.4% Al are almost zero at the same time, so that the iron-silicon-aluminum alloy has high magnetic conductivity and low coercive force, the maximum magnetic conductivity can reach 120000, and the saturated magnetic flux density can reach 1.05T. And has high resistivity and low cost, and is an ideal material for magnetic head cores. However, the magnetic performance of the Fe-Si-Al alloy is sensitive to fluctuation of components, and the Fe-Si-Al alloy has high brittleness and poor processing performance.
Since the advent of sendust, research into sendust has been increasingly conducted, and the field of sendust applications, such as uninterruptible power supplies and high frequency filters, has been expanding. However, most of the sendust powder used for production and processing is prepared by an atomization method or a crushing method. The shape of the alloy powder is spherical or irregular, so that the contact area between the powder is small, and the requirements of the wave-absorbing material cannot be met. And because the skin effect exists when the metal micropowder receives the electromagnetic wave, the particle can not be too large, otherwise, the reflection of the electromagnetic wave can be rapidly increased. Therefore, the spherical or irregular powder is processed into a sheet shape by changing the shape of the powder, so that the effective magnetic conductivity and the resistivity can be improved by utilizing the shape anisotropy, and the eddy current loss can be effectively reduced when the thickness is smaller than the skin depth. Therefore, in order to expand the application field of iron-silicon-aluminum alloy development, the research on the preparation method of the micron-sized large-diameter-thickness-ratio flaky iron-silicon-aluminum powder with high sheet forming rate and uniform particle size has important significance.
Disclosure of Invention
In order to overcome the technical defects that the ferrosilicon aluminum alloy is hard and brittle, is easy to break and break in the ball milling process and is difficult to form flaky appearance, the invention provides a preparation method of micron-sized flaky ferrosilicon aluminum powder with large diameter-thickness ratio and uniform particle size.
The preparation operation steps of the flaky ferrosilicon aluminum powder with uniform particle size, micron-sized large diameter-thickness ratio and particle morphology are as follows:
(1) cleaning the iron-silicon-aluminum alloy powder with acetone, drying, uniformly spreading on a screen, uniformly spraying a metal softening agent solution on the iron-silicon-aluminum powder with atomization equipment, wherein the atomization spraying time interval is 10-60min, and the atomization frequency is 3-8 times; the single atomization spraying amount is 5% -18% of the amount of the alloy powder;
(2) after the metal softener is sprayed for 20-60min for the last time, putting the iron-silicon-aluminum powder into an annealing furnace, annealing under the protection of nitrogen, wherein the annealing temperature is 400-500 ℃, and the heat preservation time is 3 h;
(3) ultrasonically dispersing the annealed iron-silicon-aluminum alloy powder by using ethanol as a medium;
(4) performing primary ball milling, namely adding 2-5 parts of hard amide by taking ethylene glycol as a ball milling medium, wherein the ball-material ratio is 5-16:1, and the ball milling time is 3-6 h; taking out the iron-silicon-aluminum alloy powder, washing with acetone, and drying in an oven;
(5) soaking the iron-silicon-aluminum powder obtained in the step (4) in a metal softener solution for 2-12 hours at the soaking temperature of 50-80 ℃, taking out and drying;
(6) performing secondary ball milling, namely taking 100 parts of the iron-silicon-aluminum powder obtained in the step (5), 1-2 parts of glyceryl oleate and 50-100 parts of ethanol, taking ethylene glycol as a ball milling medium, wherein the ball-material ratio is 8-20:1, and the ball milling time is 6-18 h;
(7) and (3) ultrasonically cleaning the powder obtained in the step (6) by using acetone, drying in vacuum, and annealing in vacuum at the annealing temperature of 700-800 ℃ for 2-3h to obtain the flaky iron-silicon-aluminum alloy powder with uniform particle size and the diameter-thickness ratio of 30-38: 1.
The technical scheme for further limiting is as follows:
in the step (1) or the step (5), the metal softener is glyceryl stearate or glyceryl stearate and polydimethylsiloxane oil according to a volume ratio of 2:1, mixing the mixture.
In the step (1), the atomizing equipment is a small-sized electric sprayer.
In the step (1), the first metal softener is sprayed on the surface of the sendust powder through an atomization device, the atomization spraying time interval is 10-60min, the atomization frequency is 3-8 times, and the single atomization spraying amount is 5% -18% of the alloy powder amount.
In the step (5), the soaking time for the second softening is 2-12h, and the soaking temperature is 50-80 ℃.
The beneficial technical effects of the invention are embodied in the following aspects:
1. according to the invention, before ball milling, the metal softener is added to the iron-silicon-aluminum alloy powder in an atomization spraying manner before primary ball milling, so that the hard brittleness of the powder is improved, and the hardness of the powder is further reduced and the hard brittleness of the iron-silicon-aluminum alloy powder is improved through subsequent annealing. And the powder is soaked in the metal softener before the secondary ball milling, so that the hardness and brittleness of the powder are reduced for the second time, and partial internal stress is released. The problems of low sheet forming rate and small diameter-thickness ratio caused by particle breakage due to overhigh external energy in the ball milling process of the sendust are effectively avoided.
2. The iron-silicon-aluminum powder prepared by the invention has flaky particles with uniform particle size and larger diameter-thickness ratio of 30-38: 1. As shown by comparing fig. 1 and fig. 2: after ball milling, the shape of the iron-silicon-aluminum powder is changed, the original irregular shape is changed into a sheet shape, and the thickness of the sheet is about 1 mu m. And the metal softening agent can be removed by high-temperature annealing, so that the finally obtained ferrum-silicon-aluminum is free from pollution. Compared with the traditional gas atomization sendust and broken sendust, after the gas atomization sendust and the broken sendust are pressed and formed, the flaky sendust particles are arranged layer by layer, air gaps in a magnetic ring made of the powder can be effectively reduced, and the density is improved. The sheet Fe-Si-Al with large diameter-thickness ratio can further reduce the air gap inside the magnetic ring made of the powder. Meanwhile, the shape of the sheet sendust is favorable for reducing eddy current at high frequency, and can ensure that a magnetic ring made of the powder still has higher magnetic conductivity and lower loss at high frequency.
TABLE 1
| Material | Saturation magnetization | Particle size |
| Raw powder | 1.07T | 60.22μm |
| Flaky powder | 1.28T | 32.79μm |
TABLE 2
| Material | Magnetic permeability (100 kHz) | Loss (100 kHz/100 mT) | Density of |
| Raw powder | 58 | 489.67 mw/cm3 | 5.58 g/cm3 |
| Flaky powder | 70 | 376.54 mw/cm3 | 5.89 g/cm3 |
From table 1, it can be seen that the saturation magnetization of the flaky ferrosilicon aluminum powder prepared by the present invention is increased from 1.07T to 1.28T by changing the shape anisotropy of the powder, which is significantly improved. Secondly, due to the addition of the metal softening agent, the particle size of the powder is reduced from 60.22 mu m to 32.79 mu m through short-time ball milling, and the particle size distribution of the powder is concentrated. The ratio of the particle size to the thickness of the powder is about 32: 1.
The sheet sendust powder and the raw powder prepared by the invention are prepared into a test magnetic ring for testing the magnetic performance. As can be seen from Table 2, the sheet sendust utilizes shape anisotropy to reduce the air gap inside the magnetic ring and increase the density, so that the magnetic permeability is increased from 58 to 70. In addition, the sheet sendust powder prepared by the invention has the thickness of about 1 μm, higher resistance and smaller skin depth, so the loss is reduced from 489.67 mw/cm3 to 376.54 mw/cm3 in high frequency compared with the original powder. From the above data, it is understood that the sheet sendust powder having excellent magnetic energy can be prepared by the present invention.
Drawings
FIG. 1 is an SEM topography of the Fe-Si-Al alloy powder before ball milling.
FIG. 2 is an SEM topography of the flaky ferrosilicon aluminum alloy powder obtained in example 1.
Detailed Description
The present invention will be described with reference to specific examples.
Example 1
The specific operation steps for preparing the micron-sized flaky ferrosilicon aluminum powder with large diameter-thickness ratio and uniform particle size are as follows:
(1) washing 500g of crushed iron-silicon-aluminum alloy powder with the particle size of 50-80 microns by using acetone, drying, uniformly spreading on a screen, wherein the metal softening agent is stearin, uniformly spraying the metal softening agent on the iron-silicon-aluminum powder by using an atomizing device, the atomizing device is a small electric sprayer, the atomizing spraying time interval is 15min, and the atomizing frequency is 4 times; the single atomization spraying amount is 6% of the amount of the alloy powder.
(2) And 30min after the metal softener solution is sprayed for the last time, putting the iron-silicon-aluminum powder into an annealing furnace, annealing under the protection of nitrogen, wherein the annealing temperature is 400 ℃, and the heat preservation time is 3 h.
(3) Ultrasonically dispersing the annealed iron-silicon-aluminum alloy powder by using ethanol as a medium; ultrasonic power 360W and time 15 min.
(4) Performing primary ball milling, namely taking ethylene glycol as a ball milling medium, taking 400g of iron-silicon-aluminum alloy powder, 10g of hard amide and 200g of ethylene glycol, wherein the ball-material ratio is 8:1, and the ball milling time is 3 hours; taking out the iron-silicon-aluminum alloy powder, washing with acetone, and drying in an oven.
(5) And (3) soaking the iron-silicon-aluminum powder obtained in the step (4) in a metal softening agent for 3 hours, wherein the dosage of the metal softening agent is 20% of the powder, the soaking temperature is 50 ℃, and taking out and drying.
(6) And (3) performing secondary ball milling, namely taking 350g of the iron-silicon-aluminum powder obtained in the step (5), 3g of glyceryl oleate and 300g of ethanol, and taking ethylene glycol as a ball milling medium, wherein the ball-material ratio is 8:1, and the ball milling time is 6 hours.
(7) And (3) ultrasonically cleaning the powder obtained in the step (6) by using acetone, carrying out vacuum drying at the ultrasonic power of 360W for 10min, and carrying out vacuum annealing at the annealing temperature of 700 ℃ for 2h to obtain the sheet iron-silicon-aluminum alloy powder with uniform particle size and the average diameter-thickness ratio of 38:1, wherein the thickness is 1-2 mu m as shown in figure 2.
Example 2:
the specific operation steps for preparing the micron-sized flaky ferrosilicon aluminum powder with large diameter-thickness ratio and uniform particle size are as follows:
(1) washing 500g of crushed iron-silicon-aluminum alloy powder with the particle size of 50-80 mu m by using acetone, drying, uniformly spreading on a screen, wherein the metal softener is prepared by mixing the following components in percentage by volume: 1, mixing stearin and polydimethyl silicone oil, uniformly spraying a metal softening agent on iron-silicon-aluminum powder by using atomization equipment, wherein the atomization equipment is a small electric sprayer, the atomization spraying time interval is 30min, and the atomization frequency is 3 times; the single atomization spraying amount is 10% of the amount of the alloy powder.
(2) And 30min after the metal softener solution is sprayed for the last time, putting the iron-silicon-aluminum powder into an annealing furnace, annealing under the protection of nitrogen, wherein the annealing temperature is 500 ℃, and the heat preservation time is 3 h.
(3) Ultrasonically dispersing the annealed iron-silicon-aluminum alloy powder by using ethanol as a medium; ultrasonic power 360W and time 15 min.
(4) Performing primary ball milling, namely taking ethylene glycol as a ball milling medium, taking 400g of iron-silicon-aluminum alloy powder, 15g of hard amide and 250g of ethylene glycol, wherein the ball-material ratio is 11:1, and the ball milling time is 4 hours; taking out the iron-silicon-aluminum alloy powder, washing with acetone, and drying in an oven.
(5) And (3) soaking the iron-silicon-aluminum powder obtained in the step (4) in a metal softening agent for 9 hours, wherein the dosage of the metal softening agent is 10% of the powder, the soaking temperature is 70 ℃, and taking out and drying.
(6) And (3) performing secondary ball milling, namely taking 350g of the iron-silicon-aluminum powder obtained in the step (5), 5g of glyceryl oleate and 300g of ethanol, and taking ethylene glycol as a ball milling medium, wherein the ball-material ratio is 15:1, and the ball milling time is 6 hours.
(7) And (3) ultrasonically cleaning the powder obtained in the step (6) by using acetone, carrying out ultrasonic power 360W for 10min, carrying out vacuum drying, carrying out vacuum annealing at the annealing temperature of 750 ℃ for 2.5h to obtain the sheet iron-silicon-aluminum alloy powder with uniform particle size and the average diameter-thickness ratio of 36:1, wherein the thickness is 1-1.5 mu m.
It will be understood by those skilled in the art that the foregoing is merely a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included within the scope of the present invention.
Claims (5)
1. A preparation method of flaky ferrosilicon aluminum powder with uniform particle size, micron-sized particles with large diameter-thickness ratio and morphology is characterized by comprising the following operation steps:
(1) cleaning the iron-silicon-aluminum alloy powder with acetone, drying, uniformly spreading on a screen, uniformly spraying a metal softening agent solution on the iron-silicon-aluminum powder with atomization equipment, wherein the atomization spraying time interval is 10-60min, and the atomization frequency is 3-8 times; the single atomization spraying amount is 5% -18% of the amount of the alloy powder;
(2) after the metal softener is sprayed for 20-60min for the last time, putting the iron-silicon-aluminum powder into an annealing furnace, annealing under the protection of nitrogen, wherein the annealing temperature is 400-500 ℃, and the heat preservation time is 3 h;
(3) ultrasonically dispersing the annealed iron-silicon-aluminum alloy powder by using ethanol as a medium;
(4) performing primary ball milling, namely adding 2-5 parts of hard amide by taking ethylene glycol as a ball milling medium, wherein the ball-material ratio is 5-16:1, and the ball milling time is 3-6 h; taking out the iron-silicon-aluminum alloy powder, washing with acetone, and drying in an oven;
(5) soaking the iron-silicon-aluminum powder obtained in the step (4) in a metal softener solution for 2-12 hours at the soaking temperature of 50-80 ℃, taking out and drying;
(6) performing secondary ball milling, namely taking 100 parts of the iron-silicon-aluminum powder obtained in the step (5), 1-2 parts of glyceryl oleate and 50-100 parts of ethanol, taking ethylene glycol as a ball milling medium, wherein the ball-material ratio is 8-20:1, and the ball milling time is 6-18 h;
(7) and (3) ultrasonically cleaning the powder obtained in the step (6) by using acetone, drying in vacuum, and annealing in vacuum at the annealing temperature of 700-800 ℃ for 2-3h to obtain the flaky iron-silicon-aluminum alloy powder with uniform particle size and the diameter-thickness ratio of 30-38: 1.
2. The method for preparing the flaky ferrosilicon aluminum powder with uniform particle size, micron-sized particles with large diameter-thickness ratio and particle morphology according to claim 1 is characterized in that: in the step (1) or the step (5), the metal softener is glyceryl stearate or glyceryl stearate and polydimethylsiloxane oil according to a volume ratio of 2:1, mixing the mixture.
3. The method for preparing the flaky ferrosilicon aluminum powder with uniform particle size, micron-sized particles with large diameter-thickness ratio and particle morphology according to claim 1 is characterized in that: in the step (1), the atomizing equipment is a small-sized electric sprayer.
4. The method for preparing the flaky ferrosilicon aluminum powder with uniform particle size, micron-sized particles with large diameter-thickness ratio and particle morphology according to claim 1 is characterized in that: in the step (1), the first metal softener is sprayed on the surface of the sendust powder through an atomization device, the atomization spraying time interval is 10-60min, the atomization frequency is 3-8 times, and the single atomization spraying amount is 5% -18% of the alloy powder amount.
5. The method for preparing the flaky ferrosilicon aluminum powder with uniform particle size, micron-sized particles with large diameter-thickness ratio and particle morphology according to claim 1 is characterized in that: in the step (5), the soaking time for the second softening is 2-12h, and the soaking temperature is 50-80 ℃.
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| CN113936906A (en) * | 2021-09-30 | 2022-01-14 | 安徽瑞德磁电科技有限公司 | Sphericizing preparation method of broken iron-silicon-aluminum magnetic powder particles |
| CN113936906B (en) * | 2021-09-30 | 2023-08-11 | 安徽瑞德磁电科技有限公司 | Sphericizing preparation method of broken sendust magnetic powder particles |
| CN116900322A (en) * | 2022-12-07 | 2023-10-20 | 绵阳西磁科技有限公司 | High-flattening Fe-Si-Al alloy wave-absorbing magnetic powder and preparation method thereof |
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