CN114369762A - Composite magnetic metal powder material and preparation method and application thereof - Google Patents

Composite magnetic metal powder material and preparation method and application thereof Download PDF

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CN114369762A
CN114369762A CN202210018236.2A CN202210018236A CN114369762A CN 114369762 A CN114369762 A CN 114369762A CN 202210018236 A CN202210018236 A CN 202210018236A CN 114369762 A CN114369762 A CN 114369762A
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atomization
metal powder
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magnetic metal
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CN114369762B (en
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李广帮
廖相巍
贾吉祥
尚德礼
康磊
彭春霖
宋成民
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Angang Steel Co Ltd
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/004—Very low carbon steels, i.e. having a carbon content of less than 0,01%
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/08—Ferrous alloys, e.g. steel alloys containing nickel
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/08—Cores, Yokes, or armatures made from powder
    • 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
    • H01F41/02—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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B22F2009/0824—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid with a specific atomising fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B22F2009/0848—Melting process before atomisation

Abstract

The invention relates to a composite magnetic metal powder material, a preparation method and application thereof, wherein the composite magnetic metal powder material comprises the following chemical components in percentage by weight of less than or equal to 0.015 percent of C, Si: 7.8-8.9%, Mn: 0.15-0.25%, P is less than or equal to 0.010%, S is less than or equal to 0.010%, Al: 4% -5.4%, Ni: 0.8 to 1.8 percent of the total weight of the alloy, less than or equal to 0.004 percent of the total weight of N, and the balance of iron and inevitable impurities. According to the invention, the mixed gas is introduced for compounding while the magnetic metal powder is prepared by atomization, no residue is left, the uniformity of an insulating coating layer on the surface of the powder is good, the composite magnetic metal powder material has high magnetic conductivity and low loss, the frequency stability is good, and the magnetic loss is small under high frequency; the powder material does not need to be subjected to post-treatment, and a magnetic material finished product can be directly prepared by 3D printing or directly pressed and formed.

Description

Composite magnetic metal powder material and preparation method and application thereof
Technical Field
The invention relates to the technical field of composite powder preparation, in particular to a composite magnetic metal powder material and a preparation method and application thereof.
Background
At present, power electronic devices are developed towards miniaturization, high efficiency, high frequency, high power and the like, and higher requirements are put forward on the performance of matched magnetic materials. In order to be suitable for high-power application occasions, the matched soft magnetic iron core needs to have good anti-saturation performance. Obviously, conventional soft magnetic materials of high permeability cannot meet this requirement. The general solution is to introduce an air gap in the magnetic circuit of soft magnetic material to achieve a large increase in the saturation magnetization field. However, the introduction of the air gap causes a series of problems such as electromagnetic interference, increased loss, increased temperature rise, increased noise, poor consistency and the like. Under such circumstances, the metallic soft magnetic powder core is gradually developed as a new composite soft magnetic material having a large number of distributed air gaps. The metal soft magnetic powder core is a composite soft magnetic material formed by mixing and pressing soft magnetic powder and an insulating medium through a powder metallurgy technology. The insulation coating method commonly used in the industry at present is a phosphoric acid passivation process. However, chemical corrosion of the magnetic powder causes increased loss, and the phosphate insulating layer is easily ablated at high temperature, thereby limiting the optimization of the powder core performance.
Chinese patent application No. 201310522883.8 discloses a method for coating metal magnetic powder with soft magnetic ferrite and a method for preparing soft magnetic composite material thereof, wherein the metal magnetic powder is mixed with a small amount of micron or submicron soft magnetic ferrite, and then the coating layer is formed by microwave high temperature heat treatment. The method for preparing the metal soft magnetic composite material by adopting the coating powder comprises the steps of coating the coating powder by organic matters, adding a lubricating agent, pressing and forming, and finally annealing to obtain the soft magnetic composite material. The technical scheme fully utilizes the characteristics of magnetism, high resistivity and high temperature resistance of the ferrite soft magnetic material, is a composite of two soft magnetic materials, has less nonmagnetic substances than other types of soft magnetic composite materials, and has higher heat treatment temperature, thereby having better comprehensive magnetic performance. However, in the method, the metal magnetic powder and the soft magnetic ferrite need to be mixed, and then the coating layer is formed through microwave heat treatment, and a treatment process such as adding lubricating oil is needed in the subsequent process, so that the process is complex and the cost is high.
The Chinese patent application with the application number of 201811571472.7 discloses a magnetic powder composite material and a preparation method thereof, wherein when magnetic metal melt liquid drops downwards, high-speed composite gas is introduced into a path for the magnetic metal melt liquid to drop; then collecting the magnetic metal melt, and impacting and crushing the magnetic metal melt by the high-speed atomizing gas to form a magnetic powder composite material. The magnetic powder composite material structure prepared by the method comprises the following steps: the magnetic metal powder is made of iron-silicon-aluminum metal; and the insulating layer coating film is made of silicon oxide and is coated on the surfaces of the magnetic metal powder. The preparation method omits the working procedure of post-treatment, pollution and loss: the prepared magnetic metal composite material can be directly pressed or prepared into a finished product through 3D printing without powder post-treatment. However, in the technical scheme, ethyl silicate alcohol solution needs to be prepared in advance to form an insulating layer on the surface of the powder during atomization, the technical process is complex, and the operation is difficult; and gas and liquid need to be blown in simultaneously during atomization, and the insulating layer on the surface of atomized powder is difficult to ensure uniformity.
In view of the above problems in the prior art, there is an urgent need to develop a process for preparing composite powder material, which can not leave residues in the preparation process of composite powder, has simple process, safety and reliability, can fully ensure the performance of the composite powder, and even improve the product quality.
Disclosure of Invention
The invention provides a composite magnetic metal powder material and a preparation method and application thereof, wherein mixed gas is introduced for compounding while atomizing to prepare magnetic metal powder, no residue is left, the uniformity of an insulating coating layer on the surface of the powder is good, the composite magnetic metal powder material has high magnetic conductivity, low loss, good frequency stability and small magnetic loss under high frequency; the powder material does not need to be subjected to post-treatment, and a magnetic material finished product can be directly prepared by 3D printing or directly pressed and formed.
In order to achieve the purpose, the invention adopts the following technical scheme:
a composite magnetic metal powder material comprises the following chemical components in percentage by weight, C is less than or equal to 0.015%, Si: 7.8-8.9%, Mn: 0.15-0.25%, P is less than or equal to 0.010%, S is less than or equal to 0.010%, Al: 4% -5.4%, Ni: 0.8 to 1.8 percent of the total weight of the alloy, less than or equal to 0.004 percent of the total weight of N, and the balance of iron and inevitable impurities.
The magnetic conductivity of the composite magnetic metal powder material is 110-150H/m, and the saturation magnetic flux density is 1.0-1.2T.
A preparation method of a composite magnetic metal powder material comprises the following steps:
(1) electric furnace smelting:
putting an industrial pure iron raw material into a vacuum induction furnace for smelting, controlling the vacuum degree of the vacuum induction furnace to be 1-4 Pa, carrying out alloying treatment and molten steel component adjustment after the industrial pure iron raw material is completely molten, then raising the temperature of molten steel to 1570-1590 ℃, and finishing smelting;
(2) vacuum gas atomization:
vacuum atomizing molten steel after tapping in vacuum induction furnace in supersonic closely coupled atomizing modeThe inner diameter of the outlet of the chemical guide pipe is 4-6 mm, the atomizing gas is argon, the gas pressure at the atomizing nozzle is 2.5-3.5 MPa, and the gas flow is 0.18-0.24 m3The atomization speed of the molten steel is 6-8 kg/min; the atomized metal powder is spherical powder;
(3) coating the surface of the powder material:
the surface temperature of the atomized spherical powder is 500-630 ℃ in the falling process of the atomization chamber, and at the moment, mixed gas of oxygen and carbon dioxide is blown into the atomization chamber from the side wall of the atomization chamber; the gas pressure at the mixed gas nozzle is 1.5-2.1 MPa, and the gas flow is 0.01-0.018 m3(ii)/s, obtaining a composite powder having a surface coating layer, the surface coating layer containing alumina;
(4) collecting composite powder:
and cooling, collecting and screening the composite powder to obtain the composite magnetic metal powder material.
In the step (1), ferrosilicon and ferromanganese are added during alloying treatment, wherein the ferrosilicon comprises the following chemical components in percentage by weight: 74 to 80 percent of Si, less than or equal to 0.10 percent of C, less than or equal to 0.035 percent of P, less than or equal to 0.02 percent of S, and the balance of iron and inevitable impurities; the ferromanganese comprises the following chemical components in percentage by weight: 85-92% of Mn, less than or equal to 0.20% of C, less than or equal to 0.10% of P, less than or equal to 0.002% of S, and the balance of iron and inevitable impurities.
In the step (2), molten steel after tapping of the vacuum induction furnace is poured into a tundish for vacuum atomization treatment, and the tundish is preheated to 1150-1250 ℃.
In the step (2), the proportion of the particle size of less than or equal to 45 mu m in the spherical powder is more than 50%, and the proportion of the particle size of less than or equal to 100 mu m in the spherical powder is more than 90%.
In the step (3), the ratio of oxygen to carbon dioxide in the mixed gas is 1: 2-3.
The composite magnetic metal powder material is used for preparing a magnetic material finished product through 3D printing or direct compression molding.
Compared with the prior art, the invention has the beneficial effects that:
1) the magnetic metal powder is prepared by atomization, and meanwhile, the mixed gas is introduced for compounding, no residue is left, and the uniformity of an insulating coating layer on the surface of the powder is good;
2) the composite material has high magnetic conductivity and low loss, good frequency stability and small magnetic loss at high frequency, and can ensure the performance of a magnetic material finished product;
3) the preparation process is simple, the environmental protection is good, the cost is low, the operation is easy, and the industrialized mass production can be realized.
Drawings
FIG. 1 is a schematic view showing the structure of an apparatus for use in the vacuum atomization process of the present invention.
FIG. 2 is a schematic view of the structure of the composite powder of the present invention.
In the figure: 1. smelting chamber 2, vacuum induction furnace 3, tundish 4, molten steel 5, spray plate 6, atomized powder 7, composite powder 8, atomization chamber 9, powder collector 10, vacuumizing system 11, exhaust valve 12, mixed gas blowing-in hole 13, argon blowing-in hole 14, metal powder 15 and surface coating layer
Detailed Description
The following further describes embodiments of the present invention with reference to the accompanying drawings:
the composite magnetic metal powder material comprises the following chemical components in percentage by weight, C is less than or equal to 0.015%, Si: 7.8-8.9%, Mn: 0.15-0.25%, P is less than or equal to 0.010%, S is less than or equal to 0.010%, Al: 4% -5.4%, Ni: 0.8 to 1.8 percent of the total weight of the alloy, less than or equal to 0.004 percent of the total weight of N, and the balance of iron and inevitable impurities.
The magnetic conductivity of the composite magnetic metal powder material is 110-150H/m, and the saturation magnetic flux density is 1.0-1.2T.
A preparation method of a composite magnetic metal powder material comprises the following steps:
(1) electric furnace smelting:
putting an industrial pure iron raw material into a vacuum induction furnace for smelting, controlling the vacuum degree of the vacuum induction furnace to be 1-4 Pa, carrying out alloying treatment and molten steel component adjustment after the industrial pure iron raw material is completely molten, then raising the temperature of molten steel to 1570-1590 ℃, and finishing smelting;
(2) vacuum gas atomization:
carrying out vacuum atomization treatment on molten steel after tapping of the vacuum induction furnace by adopting a supersonic tightly-coupled gas atomization mode, wherein the inner diameter of an outlet of an atomization draft tube is 4-6 mm, the atomization gas is argon, the gas pressure at an atomization nozzle is 2.5-3.5 MPa, and the gas flow is 0.18-0.24 m3The atomization speed of the molten steel is 6-8 kg/min; the atomized metal powder is spherical powder;
(3) coating the surface of the powder material:
the surface temperature of the atomized spherical powder is 500-630 ℃ in the falling process of the atomization chamber, and at the moment, mixed gas of oxygen and carbon dioxide is blown into the atomization chamber from the side wall of the atomization chamber; the gas pressure at the mixed gas nozzle is 1.5-2.1 MPa, and the gas flow is 0.01-0.018 m3(ii)/s, obtaining a composite powder having a surface coating layer, the surface coating layer containing alumina;
(4) collecting composite powder:
and cooling, collecting and screening the composite powder to obtain the composite magnetic metal powder material.
In the step (1), ferrosilicon and ferromanganese are added during alloying treatment, wherein the ferrosilicon comprises the following chemical components in percentage by weight: 74 to 80 percent of Si, less than or equal to 0.10 percent of C, less than or equal to 0.035 percent of P, less than or equal to 0.02 percent of S, and the balance of iron and inevitable impurities; the ferromanganese comprises the following chemical components in percentage by weight: 85-92% of Mn, less than or equal to 0.20% of C, less than or equal to 0.10% of P, less than or equal to 0.002% of S, and the balance of iron and inevitable impurities.
In the step (2), molten steel after tapping of the vacuum induction furnace is poured into a tundish for vacuum atomization treatment, and the tundish is preheated to 1150-1250 ℃.
In the step (2), the proportion of the particle size of less than or equal to 45 mu m in the spherical powder is more than 50%, and the proportion of the particle size of less than or equal to 100 mu m in the spherical powder is more than 90%.
In the step (3), the ratio of oxygen to carbon dioxide in the mixed gas is 1: 2-3.
The composite magnetic metal powder material is used for preparing a magnetic material finished product through 3D printing or direct compression molding.
The reasons for setting the chemical components and the content range of the composite magnetic metal powder material are as follows:
carbon: the carbon content is too high, which increases the hysteresis loss of the steel material, but if the carbon content in the steel is reduced to a very low level, the production cost is greatly increased, so the carbon content is controlled to be less than or equal to 0.015 percent.
Silicon: silicon in the steel can weaken the adverse effect of carbon, namely reduce hysteresis loss, can improve magnetic conductivity and resistivity, reduce coercive force and eddy current loss, and has the effect of preventing magnetic material from being deteriorated after long-term use, namely aging resistance. Therefore, the invention controls the silicon content to be 7.8-8.9% to ensure that a certain amount of silicon is added.
Manganese: manganese can generate manganese sulfide with sulfur in steel, so that adverse effect of sulfur is inhibited, but phase change of the steel is easily promoted when the content of manganese is too high, decarburization and desulfurization are not facilitated, and magnetic induction is reduced; the invention controls the manganese content to be 0.15-0.25%.
Sulfur and phosphorus: the sulfur and the phosphorus are harmful elements in the steel, the sulfur can cause the material to generate hot brittleness, the magnetic hysteresis loss is increased, the magnetic induction intensity is reduced, the content of the sulfur is strictly controlled, and the sulfur content is controlled to be below 0.010 percent; phosphorus can cause the material to be cold-brittle, and the content of the phosphorus is controlled to be below 0.010 percent.
Aluminum: the addition of aluminum can lead the magnetostriction performance of the magnetic material to be close to zero, ensure the performance stability at high temperature, but the brittleness of steel can be increased when the addition amount is too high, and the content of the aluminum is controlled to be 4-5.4 percent.
Nickel: the toughness of steel can be improved by adding a small amount of nickel into the steel, and the performance of the steel is improved, and the content of the nickel is controlled to be 0.8-1.8%.
Nitrogen: nitrogen can form nitride inclusions in steel, the inclusions are all nonmagnetic or weakly magnetic substances, the existence of the inclusions can cause distortion, dislocation, vacancy and internal stress of crystal lattices, and the magnetization is difficult, and the content of the inclusions is controlled to be less than or equal to 0.004 percent.
The preparation method of the composite magnetic metal powder material comprises the processes of electric furnace smelting, vacuum gas atomization, powder material surface coating treatment, composite powder collection and the like.
The device for realizing the vacuum gas atomization of the molten steel is improved on the basis of the existing atomization device, as shown in figure 1, the existing atomization device consists of a smelting chamber 1 and an atomization chamber 8, a vacuum induction furnace 2 and a tundish 4 are arranged in the smelting chamber 1, and the atomization chamber is provided with a vacuum pumping system 10 and an exhaust valve 11; the vacuum gas atomization device is provided with a mixed gas blowing hole 12 on the side wall of an atomization chamber 8; molten steel smelted by the vacuum induction furnace 2 is injected into a preheated tundish 4, an atomization guide pipe is arranged at the bottom of the tundish 4, a spray plate 5 is arranged outside the atomization guide pipe, one end of the spray plate 5 facing the atomization guide pipe is provided with an atomization nozzle, and the outer end of the spray plate 5 is provided with an argon blowing hole 13 connected with an argon pipeline; the molten steel flows out of the atomization draft tube and enters an atomization chamber 8, is atomized into powder under the blowing action of argon, and forms spherical metal powder 14 under the action of internal force when falling; while the spherical metal powder 14 continues to fall, a mixed gas composed of oxygen and carbon dioxide is blown from the mixed gas blowing hole 12 in the side wall of the atomizing chamber 8, so that the spherical metal powder 14 becomes a composite powder (as shown in fig. 2) containing alumina in the surface coating layer 15, and the composite powder falls into the powder collector 9 at the bottom of the atomizing chamber 8 to be collected.
In the vacuum gas atomization process, mixed gas of oxygen and carbon dioxide is blown in, aluminum in the spherical powder has extremely strong bonding capacity with oxygen, the carbon dioxide can also promote aluminum elements to generate aluminum oxide, and meanwhile, the carbon dioxide can also promote the temperature on the surface of the spherical powder to be rapidly reduced, and finally the composite powder is obtained, and the surface coating layer of the composite powder contains aluminum oxide.
The following examples are carried out on the premise of the technical scheme of the invention, and detailed embodiments and specific operation processes are given, but the scope of the invention is not limited to the following examples.
[ example 1 ]
In this embodiment, the chemical components of the composite magnetic metal powder material are: c: 0.015%, Si: 7.8%, Mn: 0.25%, P: 0.009%, S: 0.008%, Al 4%, Ni: 0.8%, N: 0.004%, and the balance of iron and inevitable impurities.
The composite powder material and the preparation method thereof comprise the processes of electric furnace smelting, vacuum gas atomization, powder material surface coating treatment, composite powder collection and the like, and specifically comprise the following steps:
(1) electric furnace smelting: the industrial pure iron raw material with proper components is put into a vacuum induction furnace for smelting, the vacuum degree of the vacuum induction furnace is controlled to be 1Pa in order to ensure the cleanness of steel quality, ferrosilicon, ferromanganese and other alloys are added for alloying after the industrial pure iron raw material is completely melted, the total loading amount is 40kg, the temperature of the molten steel is raised to 1570 ℃ after the components of the molten steel are adjusted, and the smelting is finished.
(2) Vacuum gas atomization: pouring molten steel into a tundish preheated to 1200 ℃ after tapping from a vacuum induction furnace, and carrying out vacuum atomization treatment, wherein the atomization adopts a supersonic tightly-coupled gas atomization mode, the inner diameter of an outlet of an atomization draft tube is 4mm, the atomization gas is argon, the gas pressure of an atomization nozzle is 3.5MPa, and the gas flow is 0.24m3And/s, the molten steel atomization speed is 6kg/min, and spherical powder with the granularity of less than or equal to 45 mu m accounting for more than 50 percent and the granularity of less than or equal to 100 mu m accounting for more than 90 percent is obtained.
(3) Coating the surface of the powder material: in the falling process of the atomized spherical powder in the atomizing chamber, the surface temperature of the spherical powder reaches 500 ℃, and at the moment, mixed gas of oxygen and carbon dioxide is blown in from the side wall of the atomizing chamber, wherein the oxygen in the mixed gas: carbon dioxide is 1:3, the gas pressure at the mixed gas nozzle is 1.5MPa, and the gas flow is 0.01m3And s. The aluminum in the spherical powder has strong binding capacity with oxygen, the carbon dioxide can promote aluminum element to generate aluminum oxide, and meanwhile, the carbon dioxide can promote the temperature on the surface of the spherical powder to be rapidly reduced, so that the composite powder containing the aluminum oxide in the surface coating layer is obtained.
(4) Collecting composite powder: and cooling and collecting the composite powder, and screening according to the use requirement to obtain the composite magnetic metal powder material.
The composite magnetic metal powder material prepared by the embodiment does not need to be subjected to post-treatment, and a magnetic material finished product can be prepared by 3D printing or directly pressed and formed.
The magnetic material finished product prepared from the composite magnetic metal powder material produced by the embodiment has the advantages of magnetic conductivity up to 110, saturation magnetic flux density of 1.0T and good comprehensive performance.
[ example 2 ]
In this embodiment, the chemical components of the composite magnetic metal powder material are: c: 0.010%, Si: 8.9%, Mn: 0.20%, P: 0.010%, S: 0.007%, Al 5.4%, Ni: 1.8%, N: 0.0032% and the balance of iron and inevitable impurities.
The composite powder material and the preparation method thereof comprise the processes of electric furnace smelting, vacuum gas atomization, powder material surface coating treatment, composite powder collection and the like, and specifically comprise the following steps:
(1) electric furnace smelting: the industrial pure iron raw material with proper components is put into a vacuum induction furnace for smelting, the vacuum degree of the vacuum furnace is controlled to be 3Pa in order to ensure the cleanness of steel quality, ferrosilicon, ferromanganese and other alloys are added for alloying after the industrial pure iron raw material is completely melted, the total loading amount is 40kg, the temperature of molten steel is raised to 1570 ℃ after the components of the molten steel are adjusted, and the smelting is finished.
(2) Vacuum gas atomization: pouring molten steel into a tundish preheated to 1200 ℃ from the steel discharged from a vacuum induction furnace, and carrying out vacuum atomization treatment, wherein the atomization adopts a supersonic tightly-coupled gas atomization mode, the inner diameter of an outlet of an atomization draft tube is 6mm, the atomization gas is argon, the gas pressure at an atomization nozzle is 3.0MPa, and the gas flow is 0.18m3And/s, the molten steel atomization speed is 8kg/min, and spherical powder with the granularity of less than or equal to 45 mu m accounting for more than 50 percent and the granularity of less than or equal to 100 mu m accounting for more than 90 percent is obtained.
(3) Coating the surface of the powder material: in the falling process of the atomized spherical powder in the atomizing chamber, the surface temperature of the spherical powder reaches 630 ℃, and at the moment, mixed gas of oxygen and carbon dioxide is blown in from the side wall of the atomizing chamber, wherein the oxygen in the mixed gas: carbon dioxide is 1:2, the gas pressure at the mixed gas nozzle is 2.1MPa, and the gas flow is 0.018m3The aluminum in the spherical powder has strong binding capacity with oxygen, and the carbon dioxide can promote the aluminum element to generate aluminum oxide and promote the surface of the spherical powderThe temperature of the surface is rapidly decreased, thereby obtaining a composite powder containing alumina in the surface coating layer.
(4) Collecting composite powder: and cooling and collecting the composite powder, and screening according to the use requirement to obtain the composite magnetic metal powder material.
The composite magnetic metal powder prepared by the embodiment does not need to be subjected to post-treatment, and a magnetic material finished product can be prepared by 3D printing or directly pressed and formed.
The magnetic material finished product prepared from the composite magnetic metal powder material produced by the embodiment has the advantages of magnetic permeability of 130, saturation magnetic flux density of 1.12T and good comprehensive performance.
[ example 3 ]
In this embodiment, the chemical components of the composite magnetic metal powder material are: c: 0.008%, Si: 8.3%, Mn: 0.15%, P: 0.008%, S: 0.009%, Al: 4.7%, Ni: 1.3%, N: 0.0038 percent, and the balance of iron and inevitable impurities.
The composite powder material and the preparation method thereof comprise the processes of electric furnace smelting, vacuum gas atomization, powder material surface coating treatment, composite powder collection and the like, and specifically comprise the following steps:
(1) electric furnace smelting: the industrial pure iron raw material with proper components is put into a vacuum induction furnace for smelting, the vacuum degree of the vacuum furnace is controlled to be 4Pa in order to ensure the cleanness of steel quality, ferrosilicon, ferromanganese and other alloys are added for alloying after the industrial pure iron raw material is completely melted, the total loading amount is 40kg, the temperature of molten steel is raised to 1580 ℃ after the adjustment of the components of the molten steel is finished, and the smelting is finished.
(2) Vacuum gas atomization: pouring molten steel into a tundish preheated to 1200 ℃ from the steel discharged from a vacuum induction furnace, and carrying out vacuum atomization treatment, wherein the atomization adopts a supersonic tightly-coupled gas atomization mode, the inner diameter of an outlet of an atomization draft tube is 5mm, the atomization gas is argon, the gas pressure of an atomization nozzle is 2.5MPa, and the gas flow is 0.21m3And/s, the molten steel atomization speed is 7kg/min, and spherical powder with the granularity of less than or equal to 45 mu m accounting for more than 50 percent and the granularity of less than or equal to 100 mu m accounting for more than 90 percent is obtained.
(3) Coating the surface of the powder material: fog mistIn the falling process of the atomized spherical powder in the atomizing chamber, the surface temperature of the spherical powder reaches 565 ℃, and at the moment, mixed gas of oxygen and carbon dioxide is blown from the side wall of the atomizing chamber, wherein the oxygen in the mixed gas: carbon dioxide 1:2.5, gas pressure at the mixed gas nozzle 1.8MPa, and gas flow rate 0.014m3And/s, the aluminum in the spherical powder has extremely strong binding capacity with oxygen, the carbon dioxide can promote aluminum element to generate alumina, and meanwhile, the carbon dioxide can promote the temperature on the surface of the spherical powder to be rapidly reduced, so that the composite powder containing the alumina in the surface coating layer is obtained.
And cooling and collecting the composite powder, and screening according to the use requirement to obtain the composite magnetic metal powder material.
The composite magnetic metal powder prepared by the embodiment does not need to be subjected to post-treatment, and a magnetic material finished product can be prepared by 3D printing or directly pressed and formed.
The magnetic material finished product prepared from the composite magnetic metal powder material produced by the embodiment has the advantages of magnetic conductivity up to 150, saturation magnetic flux density of 1.2T and good comprehensive performance.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and the inventive concepts thereof according to the present invention should be equivalent or changed within the scope of the present invention.

Claims (8)

1. The composite magnetic metal powder material is characterized in that the composite magnetic metal powder material comprises the following chemical components in percentage by weight, C is less than or equal to 0.015%, Si: 7.8-8.9%, Mn: 0.15-0.25%, P is less than or equal to 0.010%, S is less than or equal to 0.010%, Al: 4% -5.4%, Ni: 0.8 to 1.8 percent of the total weight of the alloy, less than or equal to 0.004 percent of the total weight of N, and the balance of iron and inevitable impurities.
2. The composite magnetic metal powder material of claim 1, wherein the magnetic permeability of the composite magnetic metal powder material is 110-150H/m, and the saturation magnetic flux density is 1.0-1.2T.
3. A method of preparing a composite magnetic metal powder material as claimed in claim 1 or 2, comprising the steps of:
(1) electric furnace smelting:
putting an industrial pure iron raw material into a vacuum induction furnace for smelting, controlling the vacuum degree of the vacuum induction furnace to be 1-4 Pa, carrying out alloying treatment and molten steel component adjustment after the industrial pure iron raw material is completely molten, then raising the temperature of molten steel to 1570-1590 ℃, and finishing smelting;
(2) vacuum gas atomization:
carrying out vacuum atomization treatment on molten steel after tapping of the vacuum induction furnace by adopting a supersonic tightly-coupled gas atomization mode, wherein the inner diameter of an outlet of an atomization draft tube is 4-6 mm, the atomization gas is argon, the gas pressure at an atomization nozzle is 2.5-3.5 MPa, and the gas flow is 0.18-0.24 m3The atomization speed of the molten steel is 6-8 kg/min; the atomized metal powder is spherical powder;
(3) coating the surface of the powder material:
the surface temperature of the atomized spherical powder is 500-630 ℃ in the falling process of the atomization chamber, and at the moment, mixed gas of oxygen and carbon dioxide is blown into the atomization chamber from the side wall of the atomization chamber; the gas pressure at the mixed gas nozzle is 1.5-2.1 MPa, and the gas flow is 0.01-0.018 m3(ii)/s, obtaining a composite powder having a surface coating layer, the surface coating layer containing alumina;
(4) collecting composite powder:
and cooling, collecting and screening the composite powder to obtain the composite magnetic metal powder material.
4. The method for preparing a composite magnetic metal powder material according to claim 3, wherein in the step (1), ferrosilicon and ferromanganese are added during alloying treatment, wherein the ferrosilicon comprises the following chemical components in percentage by weight: 74 to 80 percent of Si, less than or equal to 0.10 percent of C, less than or equal to 0.035 percent of P, less than or equal to 0.02 percent of S, and the balance of iron and inevitable impurities; the ferromanganese comprises the following chemical components in percentage by weight: 85-92% of Mn, less than or equal to 0.20% of C, less than or equal to 0.10% of P, less than or equal to 0.002% of S, and the balance of iron and inevitable impurities.
5. The method for preparing a composite magnetic metal powder material as claimed in claim 3, wherein in the step (2), the molten steel tapped from the vacuum induction furnace is poured into a tundish to be subjected to vacuum atomization treatment, and the tundish is preheated to 1150-1250 ℃.
6. The method according to claim 3, wherein in the step (2), the ratio of the particle size of 45 μm or less in the spherical powder is more than 50%, and the ratio of the particle size of 100 μm or less in the spherical powder is more than 90%.
7. The method for preparing the composite magnetic metal powder material according to claim 3, wherein in the step (3), the ratio of oxygen to carbon dioxide in the mixed gas is 1: 2-3.
8. Use of a composite magnetic metal powder material according to claim 1 or 2 for the preparation of a finished magnetic material by 3D printing or direct compression moulding.
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