CN112652437A - Preparation method of metal soft magnetic powder core with low forming pressure and high production efficiency - Google Patents
Preparation method of metal soft magnetic powder core with low forming pressure and high production efficiency Download PDFInfo
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- CN112652437A CN112652437A CN202110056367.5A CN202110056367A CN112652437A CN 112652437 A CN112652437 A CN 112652437A CN 202110056367 A CN202110056367 A CN 202110056367A CN 112652437 A CN112652437 A CN 112652437A
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- 239000006247 magnetic powder Substances 0.000 title claims abstract description 50
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 44
- 239000002184 metal Substances 0.000 title claims abstract description 44
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 19
- 238000002360 preparation method Methods 0.000 title abstract description 12
- 239000000843 powder Substances 0.000 claims abstract description 111
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 58
- 230000005291 magnetic effect Effects 0.000 claims abstract description 34
- 229910052742 iron Inorganic materials 0.000 claims abstract description 26
- 238000002156 mixing Methods 0.000 claims abstract description 16
- 238000005520 cutting process Methods 0.000 claims abstract description 14
- 239000011812 mixed powder Substances 0.000 claims abstract description 14
- 230000035699 permeability Effects 0.000 claims abstract description 7
- 239000003822 epoxy resin Substances 0.000 claims abstract description 6
- 229920000647 polyepoxide Polymers 0.000 claims abstract description 6
- 238000003756 stirring Methods 0.000 claims abstract description 6
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 claims abstract description 6
- 238000001125 extrusion Methods 0.000 claims abstract description 4
- 238000012216 screening Methods 0.000 claims abstract description 4
- UGKDIUIOSMUOAW-UHFFFAOYSA-N iron nickel Chemical compound [Fe].[Ni] UGKDIUIOSMUOAW-UHFFFAOYSA-N 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 5
- -1 iron-silicon-aluminum Chemical compound 0.000 claims description 3
- 238000000465 moulding Methods 0.000 abstract description 4
- 239000000463 material Substances 0.000 abstract description 3
- 239000011162 core material Substances 0.000 description 50
- 229910000519 Ferrosilicon Inorganic materials 0.000 description 13
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 7
- 239000011148 porous material Substances 0.000 description 6
- XWHPIFXRKKHEKR-UHFFFAOYSA-N iron silicon Chemical compound [Si].[Fe] XWHPIFXRKKHEKR-UHFFFAOYSA-N 0.000 description 4
- 239000011863 silicon-based powder Substances 0.000 description 4
- 239000002245 particle Substances 0.000 description 3
- 238000009826 distribution Methods 0.000 description 2
- 238000011049 filling Methods 0.000 description 2
- 230000006698 induction Effects 0.000 description 2
- 229910001004 magnetic alloy Inorganic materials 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 238000007873 sieving Methods 0.000 description 2
- 229910000976 Electrical steel Inorganic materials 0.000 description 1
- 238000004220 aggregation Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005294 ferromagnetic effect Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000000696 magnetic material Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000002923 metal particle Substances 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
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Classifications
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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
- H01F1/15341—Preparation processes therefor
- H01F1/1535—Preparation processes therefor by powder metallurgy, e.g. spark erosion
Abstract
The invention relates to a preparation method of a metal soft magnetic powder core with low forming pressure and high production efficiency, belonging to the technical field of preparation of metal soft magnetic powder cores. The operation steps are as follows: (1) screening the iron-based powder into three stages, and taking three iron-based powders according to mass percentage to obtain powder; (2) mixing the three powder materials to obtain mixed powder material; (3) adding epoxy resin and zinc stearate into the mixed powder, and uniformly stirring to obtain blank powder; (4) extruding the blank powder in a screw extruder to obtain a hollow pipe, and cutting the hollow pipe into magnetic ring green bodies; (5) baking the magnetic ring green body in a box type furnace to obtain a metal soft magnetic powder core; the density of the metal soft magnetic powder core is 5.78-7.20 g/cm3And a magnetic permeability of 48.0 to 49.5. The invention obviously reduces the molding pressure of the metal soft magnetic powder core through the granularity ratio, so the metal soft magnetic powder core can be molded in an extrusion and cutting mode, the cost is reduced, and the production efficiency is greatly improved.
Description
Technical Field
The invention belongs to the technical field of preparation of metal soft magnetic powder cores, and particularly relates to a preparation method of a metal soft magnetic powder core with low forming pressure and high production efficiency.
Background
At present, power electronic devices are rapidly developing towards miniaturization, high frequency, high power and high efficiency, which also puts higher demands on soft magnetic materials. In the traditional soft magnetic iron core material, the silicon steel sheet and the amorphous soft magnetic alloy have lower application frequency due to larger eddy current loss and noise; ferrite cannot meet the requirement of miniaturization of devices due to low saturation magnetic induction intensity; the nanocrystalline soft magnetic alloy is difficult to be widely applied due to high cost and very fragile material. The soft magnetic metal powder core prepared from ferromagnetic metal particles and a high-resistivity insulating medium by a powder metallurgy process is widely applied to various power electronic fields by virtue of the characteristics of good frequency stability, higher magnetic permeability and saturation magnetic induction intensity, excellent direct current bias performance, lower loss and the like.
When preparing a metal soft magnetic powder core, in order to increase the resistivity and reduce the eddy current loss at high frequency, the surface of the magnetic powder is usually coated with an insulating layer, which is uniform and dense. In order to improve the magnetic conductivity and reduce the hysteresis loss, the magnetic core is usually pressed by a high forming pressure of 1-2 GPa grade in a hydraulic press, so as to effectively improve the density of the magnetic core. Under such high forming pressure of the GPa order, both the inorganic acid salt and oxide insulating layers formed by inorganic insulation and the organic-coated resin insulating layers are partially destroyed, so that eddy current paths may be formed between the magnetic powders, resulting in a decrease in the electrical resistivity of the powder core and an increase in eddy current loss. In addition, a large hydraulic press is usually used in a factory for producing the powder core, on one hand, the price of the press is high, the efficiency of a production mode of repeated single pressing is low, the production cost of the metal soft magnetic powder core is high, and on the other hand, the size of a die in the hydraulic press is limited, so that the pressing size of the powder core is limited. Therefore, it is of great significance to develop a preparation process of the metal soft magnetic powder core which has low cost, high efficiency, excellent performance and no limitation of the size of forming equipment in practical production.
Disclosure of Invention
The invention provides a method for preparing a metal soft magnetic powder core with low forming pressure and high production efficiency, aiming at solving the problems of high cost and low efficiency in the existing preparation of the metal soft magnetic powder core.
The preparation operation steps of the metal soft magnetic powder core with low forming pressure and high production efficiency are as follows:
step (1) preparing powder
Screening the iron-based powder into three stages, wherein the first-stage iron-based powder is sieved by a sieve of 80-200 meshes, the second-stage iron-based powder is sieved by a sieve of 300-450 meshes, and the third-stage iron-based powder is sieved by a sieve of 625-12500 meshes;
taking 55-70% by mass of first-stage iron-based powder, 10-20% by mass of second-stage iron-based powder and 15-30% by mass of third-stage iron-based powder according to mass percent to obtain powder;
step (2) mixing the powder uniformly
Mixing the first-stage iron-based powder and the second-stage iron-based powder in a mixer for 20-30 min, adding the third-stage iron-based powder, and continuously mixing for 30-40 min to obtain mixed powder;
step (3) of preparing a green compact powder
Adding epoxy resin according to the mass of 6-8% of the mixed powder, adding zinc stearate according to the mass of 4-5 per mill of the mixed powder, and uniformly stirring for 30-40 min by using a stirrer to obtain blank powder;
step (4) preparing a magnetic ring green body
Processing the blank powder in a screw extruder, wherein the extrusion pressure is 200-300 MPa, so as to obtain a hollow pipe, and cutting the hollow pipe into magnetic ring green bodies by using a cutting machine;
step (5) preparing the metal soft magnetic powder core
Baking the magnetic ring green body in a box type furnace at the temperature of 150-250 ℃ for 5-6 hours to obtain a metal soft magnetic powder core; the density of the metal soft magnetic powder core is 5.78-7.20 g/cm3And a magnetic permeability of 48.0 to 49.5.
The technical scheme for further limiting is as follows:
in the step (1), the mixer is a V-shaped mixer.
In the step (1), the iron-based powder is more than one of iron-nickel powder, iron-silicon-aluminum powder or carbonyl iron powder.
The beneficial technical effects of the invention are embodied in the following aspects:
1. the coarse, medium and fine iron-based powders are used for carrying out particle size matching, the coarse powders are used as powder frameworks, the medium powders are used for uniformly filling pores among coarse powder particles, the fine powders are used for further filling residual pores between the coarse powders and the medium powders, so that the porosity among the iron-based powders is fully and effectively filled, and therefore the metal soft magnetic powder core can obtain the density and the magnetic conductivity which are close to those of a 1-2 GPa high-pressure molding powder core under the molding pressure of 200MPa, the performance of the metal soft magnetic powder core is remarkably improved, and the production cost is reduced.
2. The invention obviously reduces the molding pressure of the metal soft magnetic powder core through the granularity ratio, so the metal soft magnetic powder core can be molded in an extrusion and cutting mode, the powder is extruded into a hollow pipe under low pressure and then is cut into a circular ring, the dependence of mass production of the metal soft magnetic powder core on a large-scale hydraulic machine is eliminated, the cost is reduced, and meanwhile, the production efficiency of the metal soft magnetic powder core is greatly improved due to the simple and easy operability of the cutting process.
Drawings
Fig. 1 is an SEM photograph of the metal soft magnetic powder core obtained in example 1.
Fig. 2 is an SEM photograph of the metallic soft magnetic powder core obtained in example 2.
Fig. 3 is an SEM photograph of the metallic soft magnetic powder core obtained in example 3.
Fig. 4 is an appearance diagram of a typical metallic soft magnetic powder core obtained in example 3.
Detailed Description
The present invention will be described with reference to specific examples.
Example 1
The preparation operation steps of the metal soft magnetic powder core with low forming pressure and high production efficiency are as follows:
step (1) preparing powder
Screening the iron-nickel powder into three stages, wherein the first-stage iron-nickel powder is sieved by a sieve of 80-120 meshes, the second-stage iron-nickel powder is sieved by a sieve of 350-450 meshes, and the third-stage iron-nickel powder is sieved by a sieve of 2000-12500 meshes;
and taking 110g of primary iron-nickel powder, 40g of secondary iron-nickel powder and 50g of tertiary iron-nickel powder to obtain 200g of powder.
Step (2) mixing the powder uniformly
And mixing the primary iron-nickel powder and the secondary iron-nickel powder in a V-shaped mixer for 20min, adding the tertiary iron-nickel powder, and continuously mixing for 30min to obtain mixed powder.
Step (3) of preparing a green compact powder
And respectively adding 12g of epoxy resin and 0.8g of zinc stearate into 200g of mixed powder, and uniformly stirring for 30min by using a stirrer to obtain blank powder.
Step (4) preparing a magnetic ring green body
And extruding the blank powder in a screw extruder under the pressure of 300MPa to obtain a hollow pipe, and cutting the hollow pipe into magnetic ring green bodies by using a cutting machine.
Step (5) preparing the metal soft magnetic powder core
Roasting the magnetic ring green body in a box type furnace at the roasting temperature of 200 ℃ for 5 hours to obtain a metal soft magnetic powder core; the density of the metal soft magnetic powder core of this example was 7.20g/cm3And a magnetic permeability of 49.5. As can be seen from fig. 1, the obtained soft magnetic metal powder core of the present embodiment has relatively uniform powder distribution at each level, and the fine powder is distributed between the coarse powder and the medium powder to fill the pores, thereby reducing the voids in the powder core.
Example 2:
the preparation operation steps of the metal soft magnetic powder core with low forming pressure and high production efficiency are as follows:
step (1) preparing powder
Sieving the iron silicon powder into three stages, wherein the first-stage iron silicon powder is sieved by a sieve of 100 meshes to 180 meshes, the second-stage iron silicon powder is sieved by a sieve of 325 meshes to 350 meshes, and the third-stage iron silicon powder is sieved by a sieve of 625 meshes to 5000 meshes;
120g of first-level ferrosilicon powder, 20g of second-level ferrosilicon powder and 60g of third-level ferrosilicon powder are taken to obtain 200g of powder.
Step (2) mixing the powder uniformly
And (3) mixing the first-stage ferrosilicon powder and the second-stage ferrosilicon powder in a V-shaped mixer for 20min, adding the third-stage ferrosilicon powder, and continuously mixing for 35min to obtain mixed powder.
Step (3) of preparing a green compact powder
Respectively adding 16g of epoxy resin and 0.8g of zinc stearate into 200g of mixed powder, and uniformly stirring for 40min by using a stirrer to obtain blank powder.
Step (4) preparing a magnetic ring green body
And extruding the blank powder in a screw extruder under the pressure of 250MPa to obtain a hollow pipe, and cutting the hollow pipe into magnetic ring green bodies by using a cutting machine.
Step (5) preparing the metal soft magnetic powder core
Roasting the magnetic ring green body in a box type furnace at the roasting temperature of 150 ℃ for 6 hours to obtain a metal soft magnetic powder core; the density of the metallic soft magnetic powder core of this example was 6.73g/cm3And a magnetic permeability of 48.9. As can be seen from fig. 2, in the SEM photograph of the cross section of the metallic soft magnetic powder core obtained in this example, coarse powder with a larger particle size is uniformly distributed as a matrix skeleton of the entire powder core, the medium powder fills larger pores, and the fine powder is mainly distributed in the remaining fine pores, thereby effectively improving the density of the powder core.
Example 3:
the preparation operation steps of the metal soft magnetic powder core with low forming pressure and high production efficiency are as follows:
step (1) preparing powder
Sieving ferrosilicon aluminum powder into two stages, wherein the first-stage ferrosilicon aluminum powder is sieved by a sieve of 150 meshes-200 meshes, the second-stage ferrosilicon aluminum powder is sieved by a sieve of 350 meshes-400 meshes, and the third-stage powder is carbonyl iron powder and is sieved by a sieve of 2500 meshes-5000 meshes;
140g of primary ferrosilicon aluminum powder, 30g of secondary ferrosilicon aluminum powder and 30g of tertiary carbonyl iron powder are taken to obtain 200g of powder.
Step (2) mixing the powder uniformly
And (3) mixing the primary ferrosilicon aluminum powder and the secondary ferrosilicon aluminum powder in a V-shaped mixer for 30min, adding the tertiary carbonyl iron powder, and continuously mixing for 40min to obtain mixed powder.
Step (3) of preparing a green compact powder
Respectively adding 16g of epoxy resin and 1.0g of zinc stearate into 200g of mixed powder, and uniformly stirring for 35min by using a stirrer to obtain blank powder.
Step (4) preparing a magnetic ring green body
And extruding the blank powder in a screw extruder under the pressure of 200MPa to obtain a hollow pipe, and cutting the hollow pipe into magnetic ring green bodies by using a cutting machine.
Step (5) preparing the metal soft magnetic powder core
Roasting the magnetic ring green body in a box type furnace at the roasting temperature of 250 ℃ for 6 hours to obtain a metal soft magnetic powder core; the density of the metal soft magnetic powder core of this example was 5.78g/cm3And a magnetic permeability of 48.0. As can be seen from FIG. 3, the obtained soft magnetic metal powder core of the present embodiment has a relatively uniform powder distribution at each level, and the medium powder and the fine powder are filled in the pores at each position, and only slight aggregation occurs at some positions, so that the density of the powder core is still better improved as a whole. FIG. 4 shows the standard profile of the powder core prepared according to the present invention.
Claims (3)
1. A method for preparing a metal soft magnetic powder core with low forming pressure and high production efficiency is characterized by comprising the following operation steps:
step (1) preparing powder
Screening the iron-based powder into three stages, wherein the first-stage iron-based powder is sieved by a sieve of 80-200 meshes, the second-stage iron-based powder is sieved by a sieve of 300-450 meshes, and the third-stage iron-based powder is sieved by a sieve of 625-12500 meshes;
taking 55-70% by mass of first-stage iron-based powder, 10-20% by mass of second-stage iron-based powder and 15-30% by mass of third-stage iron-based powder according to mass percent to obtain powder;
step (2) mixing the powder uniformly
Mixing the first-stage iron-based powder and the second-stage iron-based powder in a mixer for 20-30 min, adding the third-stage iron-based powder, and continuously mixing for 30-40 min to obtain mixed powder;
step (3) of preparing a green compact powder
Adding epoxy resin according to the mass of 6-8% of the mixed powder, adding zinc stearate according to the mass of 4-5 per mill of the mixed powder, and uniformly stirring for 30-40 min by using a stirrer to obtain blank powder;
step (4) preparing a magnetic ring green body
Processing the blank powder in a screw extruder, wherein the extrusion pressure is 200-300 MPa, so as to obtain a hollow pipe, and cutting the hollow pipe into magnetic ring green bodies by using a cutting machine;
step (5) preparing the metal soft magnetic powder core
Baking the magnetic ring green body in a box type furnace at the temperature of 150-250 ℃ for 5-6 hours to obtain a metal soft magnetic powder core; the density of the metal soft magnetic powder core is 5.78-7.20 g/cm3And a magnetic permeability of 48.0 to 49.5.
2. A method for preparing a metallic soft magnetic powder core with low forming pressure and high production efficiency according to claim 1, wherein: in the step (1), the mixer is a V-shaped mixer.
3. A method for preparing a metallic soft magnetic powder core with low forming pressure and high production efficiency according to claim 1, wherein: in the step (1), the iron-based powder is more than one of iron-nickel powder, iron-silicon-aluminum powder or carbonyl iron powder.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113192715A (en) * | 2021-04-29 | 2021-07-30 | 安徽瑞德磁电科技有限公司 | Soft magnetic powder core with cold water pipe and preparation method |
| CN113192742A (en) * | 2021-04-29 | 2021-07-30 | 安徽瑞德磁电科技有限公司 | Preparation method of soft magnetic powder core with built-in cooling mechanism |
| CN114141525A (en) * | 2021-12-15 | 2022-03-04 | 合肥工业大学 | Preparation method of vibration-formed soft magnetic powder core |
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| CN104835616A (en) * | 2015-05-29 | 2015-08-12 | 深圳市铂科磁材有限公司 | Novel circular-ring-shaped high-power electric reactor and manufacturing method thereof |
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| CA2014975A1 (en) * | 1989-03-24 | 1991-10-19 | Ken Ikuma | Resin bound magnet and its production process |
| CN1205108A (en) * | 1996-07-23 | 1999-01-13 | 精工爱普生株式会社 | Method of manufacturing bonded magnets of rare earth metal and boned magnet of rare earth metal kind |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114141525A (en) * | 2021-12-15 | 2022-03-04 | 合肥工业大学 | Preparation method of vibration-formed soft magnetic powder core |
| CN114141525B (en) * | 2021-12-15 | 2023-03-17 | 合肥工业大学 | Preparation method of vibration-formed soft magnetic powder core |
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