CN115064328A - Low-power-consumption soft magnetic alloy material and preparation method thereof - Google Patents
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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
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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
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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
- H01F1/14766—Fe-Si based alloys
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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
- H01F1/14766—Fe-Si based alloys
- H01F1/14791—Fe-Si-Al based alloys, e.g. Sendust
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Abstract
The invention belongs to the technical field of preparation of soft magnetic alloy materials, and particularly relates to a low-power consumption soft magnetic alloy material and a preparation method thereof.
Description
Technical Field
The invention relates to the technical field of preparation of soft magnetic alloy materials, in particular to a low-power consumption soft magnetic alloy material and a preparation method thereof.
Background
With the development of communication technology and internet of things, technical requirements on devices such as filters and inductors in the related technical field are higher and higher, the problems of improving frequency spectrum efficiency and optimizing heat dissipation still need to be solved urgently, and due to the characteristics of high Bs, high magnetic conductivity, excellent current superposition, high Curie temperature and the like, the soft magnetic alloy material is widely applied to the communication technology and plays a vital role in energy conversion and information processing.
Chinese patent discloses a low-power consumption metal soft magnetic composite material and a preparation method thereof, and the publication numbers are as follows: CN108172358, the composition of the soft magnetic composite alloy magnetic powder expressed by atomic ratio satisfies the following formula: fe100-x-ySixMy, wherein M is selected from one or more of Mg, Ca and La, subscripts x and y represent atomic percentages of the corresponding alloying elements, and the following conditions are met: x is more than 0 and less than or equal to 20, y is more than 0 and less than or equal to 5, the soft magnetic alloy of the component formula has higher resistivity, an oxide layer is separated out at a crystal boundary when the soft magnetic alloy is heated in an oxygen-containing atmosphere, the integral resistivity is further improved, and the prepared magnetic powder can be directly bonded and pressed into a soft magnetic composite material, so that the soft magnetic composite material has the advantages of low power consumption, good magnetic performance and cost reduction. According to the invention, through controlling the components of alloy elements and forming the oxide layer by processing in an oxygen-containing atmosphere, the resistivity of the material is improved, so that the power consumption of the material is reduced, but through the mode of forming the oxide film, the material should be separated and segregated, the surface hardening degree of the oxide layer is high, the magnetic permeability of the material is reduced violently, the processing stress formed by the hardening of the material is increased, and the final power consumption reduction range is limited.
Chinese patent discloses a low-permeability and low-power consumption Fe-Si-Al soft magnetic material and a preparation method thereof, and the publication numbers are as follows: CN102962465, the preparation method of the soft magnetic material comprises the following steps: 1) preparing ferrosilicon aluminum powder, namely preparing a strip by adopting a high-speed cooling method of a strip throwing machine, and preparing flat ferrosilicon aluminum powder by mechanical crushing under the protection of atmosphere; 2) baking the prepared ferrum-silicon-aluminum powder until the temperature reaches 80-120 ℃, adding phosphoric acid diluent for surface treatment, and continuously baking until the ferrum-silicon-aluminum powder is dried; 2) pressing and molding the Fe-Si-Al alloy soft magnetic powder; 3) introducing hydrogen or nitrogen into the heat treatment furnace through heat treatment; 4) the epoxy resin paint is coated on the surface of the soft magnetic material, and the invention has the advantages that: the oxygen content of the powder is reduced, and the grain size of the product is reduced, so that the loss of the Fe-Si-Al product is reduced, and the product performance is improved. The invention realizes low power consumption by reducing the grain size of the material and carrying out surface phosphating treatment, but the phosphating treatment can cause the failure of the magnet under slightly severe conditions (such as high temperature and high humidity) to cause the reduction of the insulation, thereby causing the increase of the power consumption of the product.
However, the alloy soft magnetic material has low resistivity, large eddy current at high frequency and serious heating, so that the alloy soft magnetic material is limited to be used at high frequency, along with the requirements of electronic devices on high frequency and high conversion efficiency, the key is to improve the use frequency of the material and reduce the heat productivity of the material, in order to overcome the weakness, the surface of the alloy powder needs to be insulated and coated so as to improve the resistivity, avoid the electroplating climbing phenomenon, reduce the eddy current loss of the material and improve the performance of a magnetic core, so that the composite component design of the alloy powder has an important role in reducing the power consumption of the material and developing products, and therefore, the composite material technology of the soft magnetic material is necessary to develop.
Aiming at the problems, a low-power consumption soft magnetic alloy material and a preparation method thereof are provided.
Disclosure of Invention
The invention aims to provide a low-power consumption soft magnetic alloy material and a preparation method thereof.
To solve the above technical problem, according to an aspect of the present invention, the present invention provides the following technical solutions: a low-power consumption soft magnetic alloy material and a preparation method thereof comprise the following steps:
(1) selecting 0.5-2 um nucleating material, wherein the material component is any one of Fe, FeSi, FeSiCr, FeNi, FeSi and FeSiAl;
(2) treating the material in a reducing atmosphere at 300-600 ℃ for 1-6 hours;
(3) preparing a metal liquid, wherein the metal liquid comprises 75-90 wt% of Fe, 3-8 wt% of Si, 1-3 wt% of Cr, 2.4-7 wt% of P, 3.5-6 wt% of B, 0.05-0.5 wt% of Cu and 0.05-0.5 wt% of C;
(4) spraying the nucleating material into the molten metal sprayed by the atomizer through high-speed airflow, and rapidly cooling to form fruit-core-shaped powder wrapped by the molten metal;
(5) treating the fruit-pit-shaped powder in a protective atmosphere at 300-500 ℃ for 0.5-3 hours.
As a preferred scheme of the low-power consumption soft magnetic alloy material and the preparation method thereof, the invention comprises the following steps: the selected nucleating material component is any one of Fe, FeSi, FeSiCr, FeNi, FeSi and FeSiAl, wherein the particle size D50 of the powder particles is preferably 0.5-2 μm.
As a preferred scheme of the low-power consumption soft magnetic alloy material and the preparation method thereof, the invention comprises the following steps: the nucleating material is treated for 1 to 6 hours in a reducing atmosphere at a temperature of between 300 and 600 ℃.
As a preferred scheme of the low-power consumption soft magnetic alloy material and the preparation method thereof, the invention comprises the following steps: the nucleation outer part is provided with a coating metal layer, and the metal layer comprises 75-90 wt% of Fe, 3-8 wt% of Si, 1-3 wt% of Cr, 2.4-7 wt% of P, 3.5-6 wt% of B, 0.05-0.5 wt% of Cu and 0.05-0.5 wt% of C.
As a preferred scheme of the low-power consumption soft magnetic alloy material and the preparation method thereof, the invention comprises the following steps: and (3) spraying the nucleating material into the molten metal sprayed out by the atomizer through high-speed airflow, and rapidly cooling to form the core-shaped powder wrapped by the molten metal, wherein the granularity of the core-shaped powder is 5-70 um.
As a preferred scheme of the low-power consumption soft magnetic alloy material and the preparation method thereof, the invention comprises the following steps: the fruit-pit-shaped powder is treated for 0.5 to 3 hours at the temperature of 300 to 500 ℃ under the protective atmosphere.
Compared with the prior art, the invention has the beneficial effects that:
the invention forms a composite material by the control nucleation material and the cladding material, forms high impedance at the interface of the two materials, the core material has high magnetic conductivity and saturation magnetic flux, the nuclear material has certain magnetic conductivity and high saturation and low power consumption, and the alloy material with high magnetic conductivity and low loss can be prepared by using the method.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and detailed embodiments, it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without inventive exercise, wherein:
FIG. 1 is a table comparing the performance of examples and comparative examples of a low power consumption soft magnetic alloy material of the present invention and a method for preparing the same.
Detailed Description
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention, but the present invention may be practiced in other ways than those specifically described herein, and it will be apparent to those of ordinary skill in the art that the present invention may be practiced without departing from the spirit and scope of the present invention, and therefore the present invention is not limited to the specific embodiments disclosed below.
Examples
In order to make the objects, technical solutions and advantages of the present invention more apparent, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
As shown in fig. 1, a low power consumption soft magnetic alloy material and a preparation method thereof comprises the following steps:
selecting 0.5-2 um nucleating material, wherein the material component is any one of Fe, FeSi, FeSiCr, FeNi, FeSi and FeSiAl, and treating the material in a reducing atmosphere at 300-600 ℃ for 1-6 hours; preparing a metal liquid, wherein the metal liquid comprises 75-90 wt% of Fe, 3-8 wt% of Si, 1-3 wt% of Cr, 2.4-7 wt% of P, 3.5-6 wt% of B, 0.05-0.5 wt% of Cu and 0.05-0.5 wt% of C; spraying the nucleating material into the molten metal sprayed by the atomizer through high-speed airflow, and rapidly cooling to form fruit-core-shaped powder wrapped by the molten metal; the fruit-pit-shaped powder is treated for 0.5 to 3 hours at the temperature of 300 to 500 ℃ under the protective atmosphere.
Example 1:
selecting a 2um nucleating material, wherein the material component is FeSi, and treating the material in a reducing atmosphere at 300-600 ℃ for 3 hours; preparing molten metal, wherein the molten metal comprises 75 wt% of Fe, 8 wt% of Si, 3 wt% of Cr, 7 wt% of P, 6 wt% of B, 0.5 wt% of Cu and 0.5 wt% of C; spraying the nucleating material into the molten metal sprayed by the atomizer through high-speed airflow, and rapidly cooling to form fruit-core-shaped powder wrapped by the molten metal; the fruit-pit-shaped powder is treated for 0.5 to 3 hours at the temperature of 300 to 500 ℃ under the protective atmosphere.
Example 2:
selecting a 2um nucleating material, wherein the material component is Fe, and treating the material in a reducing atmosphere at 300 ℃ for 6 hours; preparing molten metal, wherein the molten metal comprises 90 wt% of Fe, 3 wt% of Si, 1 wt% of Cr, 2.4 wt% of P, 3.5 wt% of B, 0.05 wt% of Cu and 0.05 wt% of C; spraying the nucleating material into the molten metal sprayed by the atomizer through high-speed airflow, and quickly cooling to form core-shaped powder wrapped by the molten metal; the stone-like powder was treated at 300 ℃ for 0.5 hour under a protective atmosphere.
Example 3:
selecting a 2-micron nucleating material, wherein the material component is FeSiCr, and treating the material in a reducing atmosphere at 600 ℃ for 6 hours; preparing molten metal, wherein the molten metal comprises 83.7 wt% of Fe, 4 wt% of Si, 2 wt% of Cr, 5.0 wt% of P, 5.0 wt% of B, 0.1 wt% of Cu and 0.2 wt% of C; spraying the nucleating material into the molten metal sprayed by the atomizer through high-speed airflow, and rapidly cooling to form fruit-core-shaped powder wrapped by the molten metal; the stone-like powder was treated at 400 ℃ for 2 hours under a protective atmosphere.
Example 4:
selecting a 2-micron nucleating material, wherein the material component is FeSiAl, and treating the material in a reducing atmosphere at 500 ℃ for 2 hours; preparing molten metal, wherein the molten metal comprises 87.2 wt% of Fe, 3.5 wt% of Si, 1.5 wt% of Cr, 3.4 wt% of P, 4.0 wt% of B, 0.2 wt% of Cu and 0.2 wt% of C; spraying the nucleating material into the molten metal sprayed by the atomizer through high-speed airflow, and rapidly cooling to form fruit-core-shaped powder wrapped by the molten metal; the stone-like powder was treated at 400 ℃ for 1 hour under a protective atmosphere.
Example 5:
selecting a 2um nucleating material, wherein the material component is FeNi, and treating the material in a reducing atmosphere at 300 ℃ for 2 hours; preparing molten metal, wherein the molten metal comprises 84 wt% of Fe, 6.0 wt% of Si, 2.6 wt% of Cr, 3.4 wt% of P, 3.5 wt% of B, 0.3 wt% of Cu and 0.2 wt% of C; spraying the nucleating material into the molten metal sprayed by the atomizer through high-speed airflow, and rapidly cooling to form fruit-core-shaped powder wrapped by the molten metal; the stone-like powder was treated at 500 ℃ for 1 hour under a protective atmosphere.
Example 6:
selecting a 0.5um nucleating material, wherein the material component is FeSi, and treating the material in a reducing atmosphere at 450 ℃ for 3 hours; preparing molten metal, wherein the molten metal comprises 83.6 wt% of Fe, 7 wt% of Si, 1 wt% of Cr, 4.5 wt% of P, 3.5 wt% of B, 0.1 wt% of Cu and 0.3 wt% of C; spraying the nucleating material into the molten metal sprayed by the atomizer through high-speed airflow, and rapidly cooling to form fruit-core-shaped powder wrapped by the molten metal; the stone-like powder was treated at 500 ℃ for 0.5 hours under a protective atmosphere.
Example 7:
selecting a 1.5-micrometer nucleating material, wherein the material component is FeSi, and treating the material in a reducing atmosphere at 300-600 ℃ for 1-6 hours; preparing a metal liquid, wherein the metal liquid comprises 75-90 wt% of Fe, 3-8 wt% of Si, 1-3 wt% of Cr, 2.4-7 wt% of P, 3.5-6 wt% of B, 0.05-0.5 wt% of Cu and 0.05-0.5 wt% of C; spraying the nucleating material into the molten metal sprayed by the atomizer through high-speed airflow, and rapidly cooling to form fruit-core-shaped powder wrapped by the molten metal; the fruit-pit-shaped powder is treated for 0.5 to 3 hours at the temperature of 300 to 500 ℃ under the protective atmosphere.
Comparative example 1:
200g of FeSiCr water atomized powder with the D50 being 15 mu m, wherein the mass percentage of Fe is 90.5%, the mass percentage of Si is 4.5%, the mass percentage of Cr is 5%, and the powder is not subjected to other treatment.
Comparative example 2:
200g of FeSiAl gas atomization powder with the D50 being 15 mu m, wherein the mass percentage of Fe is 90.5%, the mass percentage of Si is 5.5%, the mass percentage of Al is 4%, and the powder is not subjected to other treatment.
Comparative example 3:
200g of FeSiB water atomized powder with the D50 being 15 mu m is selected, wherein the mass percentage of Fe is 87.5%, the mass percentage of Si is 4.5%, and the mass percentage of B is 8%.
Mixing the powder materials treated in the examples and the comparative examples and untreated powder materials with glue with the solid content of 4% epoxy resin, placing the mixture in a stirring tank for mixing for 10min, placing the slurry in air for air drying, placing the dried slurry in an oven for further drying, and selecting the temperature to be 100 ℃; after the powder is completely dried, crushing the powder, sieving the powder by using a 60-300-mesh sieve, and performing compression molding on the sieved powder by using a powder molding press, wherein the pressure is 1400-1800 MPa, and the size of a compression magnetic ring is 12.0mm by 8.0mm by 3.0 mm; sintering the pressed magnetic ring by using a common box type furnace, controlling the sintering temperature at 800 ℃, keeping the temperature for 2h, cooling the sintered magnetic ring to room temperature along with the furnace, evaluating the performance of the sintered magnetic ring, testing the initial permeability mu i (1V/1MHz) of a magnetic ring sample by using a 3260B type LCR tester, wherein the number of winding turns N is 13 Ts; the power consumption (50mT &300kHz) of the magnetic ring is tested by an IWATSU-SY-8218 type hysteresis loop instrument.
TABLE 1 comparison of the properties of the examples and comparative examples
The permeability of the materials obtained by the comparative examples is obviously higher than that of the comparative examples, and the power consumption is obviously lower than that of the comparative examples, which shows that the fruit-core-shaped materials are very important for high insulation and low power consumption, and meanwhile, the comparative examples 1, 2, 3, 4 and 5 show that the power consumption of FeSiAl and FeSi is lower and the power consumption of FeSiCr and other materials are higher but obviously lower than that of the comparative examples along with the change of the intrinsic permeability and the power consumption of the core materials when the core materials are different; comparing example 1 with examples 6 and 7, it can be seen that the power consumption of the material is obviously reduced after the nano core material is refined, but the magnetic permeability shows a significant decline trend, which is related to the refinement of the core material.
The invention forms a composite material by controlling the nucleation material and the cladding material, forms high impedance at the interface of the two materials, the core material has high magnetic conductivity and saturation magnetic flux, the nuclear material has certain magnetic conductivity and high saturation and low power consumption, and the alloy material with high magnetic conductivity and low loss can be prepared by using the method.
While the invention has been described above with reference to an embodiment, various modifications may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims (6)
1. A low-power consumption soft magnetic alloy material and a preparation method thereof are characterized in that: the method comprises the following steps:
(1) selecting 0.5-2 um nucleating material, wherein the material component is any one of Fe, FeSi, FeSiCr, FeNi, FeSi and FeSiAl;
(2) treating the material in a reducing atmosphere at 300-600 ℃ for 1-6 hours;
(3) preparing a metal liquid, wherein the metal liquid comprises 75-90 wt% of Fe, 3-8 wt% of Si, 1-3 wt% of Cr, 2.4-7 wt% of P, 3.5-6 wt% of B, 0.05-0.5 wt% of Cu and 0.05-0.5 wt% of C;
(4) spraying the nucleating material into the molten metal sprayed by the atomizer through high-speed airflow, and quickly cooling to form core-shaped powder wrapped by the molten metal;
(5) the fruit-pit-shaped powder is treated for 0.5 to 3 hours at the temperature of 300 to 500 ℃ under the protective atmosphere.
2. The low-power consumption soft magnetic alloy material and the preparation method thereof according to claim 1, characterized in that: the selected nucleating material component is any one of Fe, FeSi, FeSiCr, FeNi, FeSi and FeSiAl, wherein the particle size D50 of the powder particles is preferably 0.5-2 μm.
3. The low-power consumption soft magnetic alloy material and the preparation method thereof according to claim 1, characterized in that: the nucleating material is treated for 1 to 6 hours in a reducing atmosphere at a temperature of between 300 and 600 ℃.
4. The low-power consumption soft magnetic alloy material and the preparation method thereof according to claim 1, characterized in that: a metal layer is coated outside the nucleation layer, and the metal layer comprises 75-90 wt% of Fe, 3-8 wt% of Si, 1-3 wt% of Cr, 2.4-7 wt% of P, 3.5-6 wt% of B, 0.05-0.5 wt% of Cu, and 0.05-0.5 wt% of C.
5. The low-power consumption soft magnetic alloy material and the preparation method thereof according to claim 1, characterized in that: and (3) spraying the nucleating material into the molten metal sprayed out by the atomizer through high-speed airflow, and rapidly cooling to form the core-shaped powder wrapped by the molten metal, wherein the granularity of the core-shaped powder is 5-70 um.
6. The low-power consumption soft magnetic alloy material and the preparation method thereof according to claim 1, characterized in that: the fruit-pit-shaped powder is treated for 0.5 to 3 hours at the temperature of 300 to 500 ℃ under the protective atmosphere.
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