CN113878125A - 一种铁硅铬锗钛合金软磁粉末气雾化的制备方法 - Google Patents

一种铁硅铬锗钛合金软磁粉末气雾化的制备方法 Download PDF

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CN113878125A
CN113878125A CN202111204619.0A CN202111204619A CN113878125A CN 113878125 A CN113878125 A CN 113878125A CN 202111204619 A CN202111204619 A CN 202111204619A CN 113878125 A CN113878125 A CN 113878125A
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黄莹祥
王冲
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Quanzhou Xinhang New Material Technology Co ltd
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Abstract

本发明涉及一种铁硅铬锗钛合金软磁粉末气雾化的制备方法，包括如下步骤：1）将含有铁、硅、铬、锗、钛的软磁合金粉末原料加入中频感应炉内，采用抽真空和氩气保护冶炼得到合金液；2）在氩气保护条件下，将合金液浇注入雾化塔内，浇注过程中，通过高压超音速氩气，作用于合金液柱流，将合金液柱流分散、破碎、冷却成近球形的合金软磁粉末。此方法可以制备高振实密度，高磁导率，低损耗的铁硅铬锗钛合金粉末，可作为电感器件的粉末原材料得到广泛应用。

Description

一种铁硅铬锗钛合金软磁粉末气雾化的制备方法
技术领域
本发明涉及软磁合金粉末技术领域，更具体地说是指一种铁硅铬锗钛合金软磁粉末气雾化的制备方法。
背景技术
目前，金属软磁粉末通常是以铁硅铬为主，采用化学反应法、熔体雾化法、机械破碎法和点解沉积法等制备方法制成，其中，熔体雾化法制备合金粉末拥有与既定熔融合金完全相同的化学成分，还具有典型的快速凝固组织，合金成分范围宽，粉末形貌球形度好，粒度分布宽的特点，被广泛的应用当下金属软磁粉末制作。
但是，随着科技的发展，电子元器件的应用越来越广，且随着产品性能的提高，对电子元器件所用的磁性材料要求越来越高，特别是针对不同电子产品其功能不同，对金属软磁粉末的材料性质要求也不同，如部分电感器件对软磁材料需要较高的磁导率、饱和特性和耐损耗，而通过上述熔体雾化法制取的铁硅铬软磁粉末，其存在粉末振实密度低、磁导率低、耐损耗低和易饱和等缺陷，无法满足客户实际需求。
发明内容
本发明提供一种铁硅铬锗钛合金软磁粉末气雾化的制备方法，以解决现有金属软磁粉末存在的振实密度低、磁导率低和耐损耗低等缺陷。
本发明采用如下技术方案：
一种铁硅铬锗钛合金软磁粉末气雾化的制备方法，包括如下步骤：
1）将含有铁、硅、铬、锗、钛的软磁合金粉末原料加入中频感应炉内，采用抽真空和氩气保护冶炼得到合金液。
2）在氩气保护条件下，将合金液浇注入雾化塔内，浇注过程中，通过高压超音速氩气，作用于合金液柱流，将合金液柱流分散、破碎、冷却成近球形的合金软磁粉末。
上述，最终制成的合金软磁粉末质量比为：铬0.1-10%，硅2-8%，锗0.1-8%，钛0.1-8%，铁余量。
进一步地，所述1）冶炼过程中，先将铁、铬、硅按顺序先后加入中频感应炉，密封炉体，中频感应炉的坩埚加热，炉体内抽真空至1-100Pa，充入氩气至100-102KPa；感应炉内原料完全熔化，并在温度达到1640-1660度时，加入锗、钛；镇静除渣后，得到合金液。
进一步地，所述步骤2）雾化塔的雾化桶加装变频引风机、排气管道和截止阀，将合金液浇注入雾化塔内，通过变频引风机、排气管道和截止阀配合将氩气形成高压超音速气体，并作用于金属液柱流，将金属液柱流分散、破碎、冷却成球形或近球形的合金软磁粉末。
进一步地，浇注过程中漏包采用氩气保护，漏眼直径5-8毫米。
进一步地，雾化过程中高压氩气的压力为3-8MPa；流量800-3000M3/Hr，所述超音速气体的速度为1—5马赫。
由上述对本发明结构的描述可知，和现有技术相比，本发明具有如下优点：
本发明所制备的合金软磁粉末相较于传统的铁硅铬软磁粉末，由于锗、钛元素的加入，可以到对铁硅铬合金细化晶粒改善组织缺陷的效果，并且采用真空熔炼氩气雾化，降低雾化过程中的氧化氮化以及金属和水的反应，明显降低了合金的夹杂物含量，同时由于气雾化工艺更利于形球，冷却速度慢更利于降低组织缺陷，配合锗、钛元素的加入，能够进一步改善软磁粉末在软磁电感器件应用中的磁导率特性、饱和特性和磁损。
具体实施方式
下面说明本发明实施例的具体实施方式。
一种铁硅铬锗钛合金软磁粉末气雾化的制备方法，包括如下步骤:
1) 将含有铁、硅、铬、锗、钛的软磁合金粉末原料加入中频感应炉内，采用抽真空和氩气保护冶炼得到合金液。
进一步，先将铁、铬、硅按顺序先后加入中频感应炉，密封炉体，中频感应炉的坩埚加热，炉体内抽真空至1-100Pa，充入氮气至100-102KPa；感应炉内原料完全熔化，并在温度达到1640-1660度时，加入锗、钛；镇静除渣后，得到合金液。
上述冶炼中，锗、钛两种元素因容易氧化，在熔炼过程中，要往相对靠后的顺序加入，并通过抽真空和氩气保护，以降低冶炼过程中锗、钛的氧化，降低合金液中的氧化物杂质。
2）在氩气保护条件下，将合金液浇注入雾化塔内，浇注过程中，通过高压超音速氩气，作用于合金液柱流，将合金液柱流分散、破碎、冷却成近球形的合金软磁粉末。制成的软磁合金粉末原料质量比为：铬0.1-10%，硅2-8%，锗0.1-8%，钛0.1-8%，铁余量。
更具体的，雾化塔的雾化桶加装变频引风机、排气管道和截止阀。将合金液浇注入雾化塔内，浇注过程中漏包的漏眼直径5-8毫米，氩气作为破碎气体，通过变频引风机、排气管道和截止阀配合将氩气形成高压超音速气体，作为优选雾化过程中高压氩气的压力为3-8MPa；流量800-3000M3/Hr，所述超音速气体的速度为1—5马赫。合金液柱流在高压超音速气体作用下，被分散、破碎、冷却形成球形或近球形的合金软磁粉末。
本发明制得的合金软磁粉末相较于传统的铁硅铬软磁粉末，由于锗、钛元素的加入，可以到对铁硅铬合金细化晶粒改善组织缺陷的效果，并且采用真空熔炼氩气雾化，降低雾化过程中的氧化氮化以及金属和水的反应，明显降低了合金的夹杂物含量，同时由于气雾化工艺更利于形球，冷却速度慢更利于降低组织缺陷，配合锗、钛元素的加入，能够进一步改善软磁粉末在软磁电感器件应用中的磁导率特性、饱和特性和磁损。
经检测，下面为本发明所制制成的产品B与现有雾化法制成的铁硅铬产品A的材料性能对比表。
Figure DEST_PATH_IMAGE002
上述仅为本发明的具体实施方式，但本发明的设计构思并不局限于此，凡利用此构思对本发明进行非实质性的改动，均应属于侵犯本发明保护范围的行为。

Claims (6)

1.一种铁硅铬锗钛合金软磁粉末气雾化的制备方法，其特征在于，包括如下步骤：
1）将含有铁、硅、铬、锗、钛的软磁合金粉末原料加入中频感应炉内，采用抽真空和氩气保护冶炼得到合金液；
2）在氩气保护条件下，将合金液浇注入雾化塔内，浇注过程中，通过高压超音速氩气，作用于合金液柱流，将合金液柱流分散、破碎、冷却成近球形的合金软磁粉末。
2.根据权利要求 1 所述的一种铁硅铬锗钛合金软磁粉末气雾化的制备方法，其特征在于：所述步骤2）制成的合金软磁粉末质量比为：铬0.1-10%，硅2-8%，锗0.1-8%，钛0.1-8%，铁余量。
3.根据权利要求 1 所述的一种铁硅铬锗钛合金软磁粉末气雾化的制备方法，其特征在于：所述1）冶炼过程中，先将铁、铬、硅按顺序先后加入中频感应炉，密封炉体，中频感应炉的坩埚加热，炉体内抽真空至1-100Pa，充入氩气至100-102KPa；感应炉内原料完全熔化，并在温度达到1640-1660度时，加入锗、钛；镇静除渣后，得到合金液。
4.根据权利要求 1 所述的一种铁硅铬锗钛合金软磁粉末气雾化的制备方法，其特征在于：所述步骤2）雾化塔的雾化桶加装变频引风机、排气管道和截止阀，将合金液浇注入雾化塔内，通过变频引风机、排气管道和截止阀配合将氩气形成高压超音速气体，并作用于金属液柱流，将金属液柱流分散、破碎、冷却成球形或近球形的合金软磁粉末。
5.根据权利要求 4 所述的一种铁硅铬锗钛合金软磁粉末气雾化的制备方法，其特征在于：浇注过程中漏包采用氩气保护，漏眼直径5-8毫米。
6.根据权利要求 4 所述的一种铁硅铬锗钛合金软磁粉末气雾化的制备方法，其特征在于：雾化过程中高压氩气的压力为3-8MPa；流量800-3000M3/Hr，所述超音速气体的速度为1—5马赫。
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