CN112321292A - 一种烧结铁氧体预烧料的制造方法 - Google Patents

一种烧结铁氧体预烧料的制造方法 Download PDF

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CN112321292A
CN112321292A CN202011221662.3A CN202011221662A CN112321292A CN 112321292 A CN112321292 A CN 112321292A CN 202011221662 A CN202011221662 A CN 202011221662A CN 112321292 A CN112321292 A CN 112321292A
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strontium carbonate
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刘辉
张鹏杰
魏汉中
全小康
李亚峰
李炳山
孙威
王永齐
牛辉辉
张文浩
王继全
熊君
王倩
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Beikuang Magnets Fuyang Co ltd
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Abstract

本发明提供一种烧结铁氧体预烧料的制造方法，包括主原材料和添加剂，主原材料为铁红和碳酸锶。通过添加碳酸钙，能够促进液相烧结，解决摩尔比大于6时反应活性差、不能获得高的饱和磁化强度的问题。同时由于摩尔比大于6，预烧料经过微粉碎获得的料浆不产生胶状物，湿压成型过程中易于排水，成型效率明显提高。即通过添加碳酸钙，一方面提高了预烧料的饱和磁化强度，同时在微粉碎时，能够将粒度研磨到0.6μm及以下，充分发挥出材料应有的性能，从而获得了优异的磁体性能。

Description

一种烧结铁氧体预烧料的制造方法
技术领域
本发明涉及永磁材料技术领域，具体为一种烧结铁氧体预烧料的制造方法。
背景技术
M型永磁铁氧体按照化学成分可分为锶铁氧体和钡铁氧体。永磁铁氧体粉末在磁场中成型后烧结，可得到各向异性烧结铁氧体磁铁。作为烧结磁体使用的铁氧体材料，已知有六方晶系M型Sr铁氧体和Ba铁氧体。其通式可以表示为AO nFe2O3，n是摩尔比，A元素可以是Sr或Ba。目前应用最为广泛的是锶铁氧体。工业上，锶铁氧体是以铁红或铁鳞与碳酸锶为主要原料，通过陶瓷工艺制备得到。其理论分子式为：SrFe12O19，也就是原材料配比中Fe2O3和SrCO3的摩尔比理论值应为6。
按照成型方式的不同，可分为干法成型和湿法成型。干法成型就是将铁氧体粉末与粘结剂混合均匀后，直接在磁场中成型，成型效率高，但由于粉末间的摩擦力大，不利于粉末在磁场中转动，导致取向度差，产品性能低。相比干法成型，湿法成型时铁氧体粉末处于分散介质(水、酒精)的包围中，由于分散介质的存在，粉末在磁场中易于转动，能够获得很好的取向度，产品性能高，故湿法成型的磁铁应用十分广泛，应用领域遍及汽车，家电，电动工具、信息、医疗、玩具等领域。
对于湿法成型的工艺而已，要获得理想的性能，主要有两个途径：一是提高材料的饱和磁化强度；二是降低细磨粒度，一般来说，经湿式微粉碎得到的料浆的平均粒径越细，产品性能越高。
为了提高饱和磁化强度，以往从业技术人员一般将摩尔比设定为小于6，使晶格点阵上产生一定的空位，以提高离子扩散速度，即提高反应活性，已达到提高反应完全度的目的，从而提高性能。但是摩尔比设定小于6导致部分碳酸锶没有反应，而存留在铁氧体中。由于铁氧体的磁性来源于铁离子，故这部分存留的碳酸锶不仅对饱和磁化强度没有贡献，而且是对资源的浪费。
与此同时，为了进一步提高性能，一般而言粒度越细越好。但是当摩尔比设定小于6的预烧料在微粉碎时，特别是当平均粒度小于0.7μm，在晶界上残存的那部分碳酸锶被释放出来，和水发生反应，生成了氢氧化锶，当料浆经过长时间沉淀，就产生了大量的Sr(OH)2，形成胶状物，从而导致料浆在压型过程中，不利于水的排出，造成生产效率急剧下降。摩尔比越低，残存的碳酸锶也就越多，导致生成的氢氧化锶越多，排水越困难，生产效率下降越厉害。
而当摩尔比设定大于6，由于碳酸锶反应完全，因而在微粉碎时，没有碳酸锶被释放出来，不会形成胶状物，料浆在压型容易，效率极大提高。但是当摩尔比设定大于6，晶格点阵上的空位很少，离子扩散速度慢，即反应活性较差，不利于饱和磁化强度的提高，磁性能(特别是Br)较摩尔比小于6的更低。且富余的氧化铁容易生产α-Fe2O3相(软磁相)，从而对磁性能产生不利影响。产品性能大大低于摩尔比设定小于6的情况。
因此现有技术的摩尔比一般设定为小于6，同时为了保证生产效率，从业人员只能成型料浆的粒度控制在0.7-0.8μm，再这个粒度下，无法发挥出材料的应有性能，这这就导致了材料的浪费。
综述所述，在不增加成本的情况下(即不添加稀土的情况下)，现有技术无法既得到适合于大生产的、成型效率高的、同时性能优异的预烧料。
发明内容
本发明所解决的技术问题在于提供一种具有优异磁性能、同时易于成型的烧结铁氧体预烧料的制造方法，以解决上述背景技术中提出的问题。
本发明所解决的技术问题采用以下技术方案来实现：一种烧结铁氧体预烧料的制造方法,包括主原材料和添加剂，主原材料为铁红和碳酸锶，其制造方法包括以下步骤：
步骤一:按配比称取铁红和碳酸锶，铁红与碳酸锶的质量百分比为6.005-6.20，铁红中Fe2O3的含量为99wt％，碳酸锶z中SrCO3的含量为98wt％，同时称取定量的一次添加剂，所述一次添加剂为CaCO3和SiO2；
步骤二:将上述材料放入强混机内干式混合均匀，造粒，并于空气中在1250℃-1350℃的温度下预烧，获得预烧料；
步骤三:将上述预烧料使用干式球磨机破碎，筛分，得到粒度为3-7μm的预烧料粗粉；
步骤四:将预烧料粗粉连同二次添加剂一起投入球磨机中，以水为介质进行微粉碎，粒度控制在0.6μm；
步骤五:将微粉碎后的料浆含水率调整为40％，置于磁场中成型，施加磁场，压制成型，得到成型体；
步骤六:将成型体置于烧结炉中烧结，升温速率为6℃/min，烧结温度为1220℃，保温2小时，随炉自然冷却至室温，随后对烧结磁体的上下表面进行磨加工，获得烧结铁氧体磁体。
作为本发明的优选方案为：所述一次添加剂中的CaCO3的添加量以主原材料重量计为0.1wt％-0.6wt％，一次添加剂中的SiO2的添加量以主原材料重量计为0wt％-0.3wt％。
作为本发明的优选方案为：所述步骤四中的二次添加剂的组成为：CaCO3的添加量以粗粉重量计为1.2wt％，SiO2的添加量以粗粉重量计为0.3wt％，H3BO3的添加量以粗粉重量计为0.2wt％，Al2O3的添加量以粗粉重量计为0.3wt％。
作为本发明的优选方案为：所述步骤五中的磁场强度为8000-10000Oe，成型压力为7-9MPa。
与现有技术相比，本发明的有益效果是：通过添加碳酸钙，能够促进液相烧结，解决摩尔比大于6时反应活性差、不能获得高的饱和磁化强度的问题。同时由于摩尔比大于6，预烧料经过微粉碎获得的料浆不产生胶状物，湿压成型过程中易于排水，成型效率明显提高。即通过添加碳酸钙，一方面提高了预烧料的饱和磁化强度，同时在微粉碎时，能够将粒度研磨到0.6μm及以下，充分发挥出材料应有的性能，从而获得了优异的磁体性能。
具体实施方式
为了使本发明的实现技术手段、创作特征、达成目的与功效易于明白了解，进一步阐述本发明。
实施例1
步骤一：称取主原材料，其中铁红86.82wt％，碳酸锶13.18wt％，铁红中Fe2O3的含量为99wt％，碳酸锶z中SrCO3的含量为98wt％。同时称取0.4wt％(以主原材料重量计)的CaCO3，0.2wt％(以主原材料重量计)的SiO2。用强混机干式混合均匀，造粒，于空气中1250℃预烧，获得预烧料，测量预烧料的饱和磁化强度如表1所示；
步骤二：将上述预烧料使用干式球磨机破碎，筛分，得到粒度为3-7μm的预烧料粗粉；
步骤三：将预烧料粗粉连同二次添加剂一起投入球磨机中，以水为介质进行微粉碎，粒度控制在0.6μm；所述二次添加剂的组成为：1.2wt％(以粗粉重量计)的CaCO3，0.3wt％(以粗粉重量计)的SiO2，0.2wt％(以粗粉重量计)的H3BO3，0.3wt％(以粗粉重量计)的Al2O3；
步骤四：将微粉碎后的料浆含水率调整为40％，置于磁场中成型，施加磁场，压制成型，磁场强度为8000-10000Oe，成型压力为7-9MPa，得到成型体；
步骤五：将成型体置于烧结炉中烧结，升温速率为6℃/min，烧结温度为1220℃，保温2小时，随炉自然冷却至室温，随后对烧结磁体的上下表面进行磨加工，获得烧结铁氧体磁体。测量磁性能的结果如表2所示。
对比例1
称取主原材料，其中铁红86.82wt％，碳酸锶13.18wt％，铁红中Fe2O3的含量为99wt％，碳酸锶中SrCO3的含量为98wt％。同时称取0.2wt％(以主原材料重量计)的SiO2。用强混机干式混合均匀，造粒，于空气中1300℃预烧，获得预烧料；其余步骤和实施例1相同。
对比例2
称取主原材料，其中铁红86.24wt％，碳酸锶13.76wt％，铁红中Fe2O3的含量为99wt％，碳酸锶中SrCO3的含量为98wt％。同时称取0.4wt％(以主原材料重量计)的CaCO3，0.2wt％(以主原材料重量计)的SiO2。用强混机干式混合均匀，造粒，于空气中1250℃预烧，获得预烧料；其余步骤和实施例1相同。
对比例3
称取主原材料，其中铁红86.24wt％，碳酸锶13.76wt％，铁红中Fe2O3的含量为99wt％，碳酸锶中SrCO3的含量为98wt％。同时称取0.2wt％(以主原材料重量计)的SiO2。用强混机干式混合均匀，造粒，于空气中1250℃预烧，获得预烧料；其余步骤和实施例1相同。
表1实施例1和对比例1～3的饱和磁化强度对比
Figure BDA0002762227790000051
表2实施例1和对比例1～3的磁性和成型时间对比
Figure BDA0002762227790000052
实施例2
称取主原材料，其中铁红分别为86.24wt％、86.55wt％、86.63wt％、86.72wt％、86.82wt％、86.91wt％，碳酸锶分别为13.76wt％、13.45wt％、13.37wt％、13.23wt％、13.18wt％、13.09wt％，铁红中Fe2O3的含量为99wt％，碳酸锶中SrCO3的含量为98wt％。同时称取0.4wt％(以主原材料重量计)的CaCO3，0.2wt％(以主原材料重量计)的SiO2。用强混机干式混合均匀，造粒，于空气中1250℃预烧，获得预烧料。其余步骤和实施例1相同。测量磁性能的结果如表3所示。
表3实施例2的磁性能和成型时间统计
Figure BDA0002762227790000053
Figure BDA0002762227790000061
实施例3
称取主原材料，其中铁红86.63wt％，碳酸锶13.37wt％，铁红中Fe2O3的含量为99wt％，碳酸锶中SrCO3的含量为98wt％。同时分别称取0wt％、0.1wt％、0.2wt％、0.3wt％、0.4wt％、0.5wt％、0.6wt％、1.0wtwt％(以主原材料重量计)的CaCO3，0.2wt％(以主原材料重量计)的SiO2。用强混机干式混合均匀，造粒，于空气中1250℃预烧，获得预烧料。其余步骤和实施例1相同。测量磁性能的结果如表4所示。
表4实施例3的磁性能和成型时间统计
Figure BDA0002762227790000062
实施例4
称取主原材料，其中铁红86.63wt％，碳酸锶13.37wt％，铁红中Fe2O3的含量为99wt％，碳酸锶中SrCO3的含量为98wt％。称取0.4wt％(以主原材料重量计)的CaCO3，同时分别称取0wt％、0.1wt％、0.2wt％、0.3wt％、0.4wt％(以主原材料重量计)的SiO2。用强混机干式混合均匀，造粒，于空气中1250℃预烧，获得预烧料。其余步骤和实施例1相同。测量磁性能的结果如表5所示。
表5实施例3的磁性能和成型时间统计
Figure BDA0002762227790000071
以上显示和描述了本发明的基本原理和主要特征和本发明的优点。本行业的技术人员应该了解，本发明不受上述实施例的限制，上述实施例和说明书中描述的只是说明本发明的原理，在不脱离本发明精神和范围的前提下，本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明范围内。本发明的要求保护范围由所附的权利要求书及其等效物界定。

Claims (4)

1.一种烧结铁氧体预烧料的制造方法，其特征在于：包括主原材料和添加剂，主原材料为铁红和碳酸锶，其制造方法包括以下步骤：
步骤一:按配比称取铁红和碳酸锶，铁红与碳酸锶的质量百分比为6.005-6.20，铁红中Fe2O3的含量为99wt％，碳酸锶z中SrCO3的含量为98wt％，同时称取定量的一次添加剂，所述一次添加剂为CaCO3和SiO2；
步骤二:将上述材料放入强混机内干式混合均匀，造粒，并于空气中在1250℃-1350℃的温度下预烧，获得预烧料；
步骤三:将上述预烧料使用干式球磨机破碎，筛分，得到粒度为3-7μm的预烧料粗粉；
步骤四:将预烧料粗粉连同二次添加剂一起投入球磨机中，以水为介质进行微粉碎，粒度控制在0.6μm；
步骤五:将微粉碎后的料浆含水率调整为40％，置于磁场中成型，施加磁场，压制成型，得到成型体；
步骤六:将成型体置于烧结炉中烧结，升温速率为6℃/min，烧结温度为1220℃，保温2小时，随炉自然冷却至室温，随后对烧结磁体的上下表面进行磨加工，获得烧结铁氧体磁体。
2.根据权利要求1所述的一种烧结铁氧体预烧料的制造方法，其特征在于：所述一次添加剂中的CaCO3的添加量以主原材料重量计为0.1wt％-0.6wt％，一次添加剂中的SiO2的添加量以主原材料重量计为0wt％-0.3wt％。
3.根据权利要求1所述的一种烧结铁氧体预烧料的制造方法，其特征在于：所述步骤四中的二次添加剂的组成为：CaCO3的添加量以粗粉重量计为1.2wt％，SiO2的添加量以粗粉重量计为0.3wt％，H3BO3的添加量以粗粉重量计为0.2wt％，Al2O3的添加量以粗粉重量计为0.3wt％。
4.根据权利要求1所述的一种烧结铁氧体预烧料的制造方法，其特征在于：所述步骤五中的磁场强度为8000-10000Oe，成型压力为7-9MPa。
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