CN117790103B - Corrosion-resistant iron-silicon-chromium alloy soft magnetic material and preparation method thereof - Google Patents

Corrosion-resistant iron-silicon-chromium alloy soft magnetic material and preparation method thereof Download PDF

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CN117790103B
CN117790103B CN202311861097.0A CN202311861097A CN117790103B CN 117790103 B CN117790103 B CN 117790103B CN 202311861097 A CN202311861097 A CN 202311861097A CN 117790103 B CN117790103 B CN 117790103B
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magnetic material
corrosion
chromium alloy
ferrosilicon
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CN117790103A (en
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鄢传军
吴天宝
周文良
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Guangdong Fanrui New Material Co ltd
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Abstract

The invention belongs to the technical field of soft magnetic alloy materials, and discloses a corrosion-resistant iron-silicon-chromium alloy soft magnetic material and a preparation method thereof. The preparation method comprises the following steps: adding ferrosilicon chromium alloy powder into a solvent to be uniformly dispersed, then adding sodium silicate or silicate ester and a vinyl end-capping agent, stirring and uniformly mixing, and adding an acid catalyst under the stirring condition to carry out polymerization equilibrium reaction; after the reaction is finished, filtering, washing and drying are carried out to obtain vinyl MQ silicon resin coated alloy powder; and uniformly mixing the obtained vinyl MQ silicon resin coated alloy powder, hydrogen-containing silicone oil and a catalyst, performing hot pressing, curing and forming, and then sintering to obtain the corrosion-resistant iron-silicon-chromium alloy soft magnetic material. According to the invention, the MQ silicon resin and the cross-linked polysiloxane are adopted to carry out double coating modification on the alloy powder, and the Fe-Si-Cr alloy soft magnetic material coated by the double SiO 2 is obtained after sintering, so that the corrosion resistance and the magnetic property of the alloy soft magnetic material can be obviously improved.

Description

Corrosion-resistant iron-silicon-chromium alloy soft magnetic material and preparation method thereof
Technical Field
The invention belongs to the technical field of soft magnetic alloy materials, and particularly relates to a corrosion-resistant iron-silicon-chromium alloy soft magnetic material and a preparation method thereof.
Background
The Fe-Si-Cr alloy powder is one kind of common alloy material with excellent magnetic performance and mechanical performance and may be used widely in electronic, communication, automobile, aviation, etc. Although the ferrosilicon chromium magnetic powder has higher resistivity, the ferrosilicon chromium magnetic powder still has the problems of large eddy current and serious heat generation when being used at high frequency. With the increase of the requirements of electronic devices for high frequency and high conversion efficiency, it is important to increase the use frequency of materials and reduce the heat productivity of materials. In order to improve the service performance of the ferrosilicon chromium magnetic powder core under high frequency, insulating coating or internal crystallization is carried out on the surface of the alloy powder material, and insulating precipitated phases are added among particles so as to improve the resistivity of the ferrosilicon chromium magnetic powder core, reduce eddy currents among the particles and inside the particles of the alloy material, reduce loss, reduce heating and improve the energy conversion efficiency.
Patent CN 116825525A discloses a preparation method of FeSiCr soft magnetic alloy powder, firstly, baking the alloy powder at 500-800 ℃ to obtain metal oxide coated alloy powder; and then sequentially carrying out phosphoric acid coating and epoxy resin coating treatment on the alloy powder with the metal oxide coating to obtain the multi-layer coated FeSiCr soft magnetic alloy powder. By the treatment, the saturation of FeSiCr soft magnetic alloy powder is improved, and the loss is reduced. However, the high-temperature oxidation treatment can cause the magnetic conductivity of the alloy powder to be reduced, and the magnetic powder core prepared by the alloy powder after the phosphoric acid coating and the epoxy resin coating treatment is poor in corrosion resistance and rust resistance.
The loss can be reduced and the corrosion resistance and rust resistance can be improved by carrying out silica coating treatment on the surface of the alloy powder, but the silica coating treatment at present is mainly prepared by silica sol, such as the methods disclosed in CN 112530655A and CN 104028750B, but the directly generated SiO 2 coating layer has larger brittleness, and is easy to break in the compression molding process, so that the insulation coating effect is reduced; meanwhile, the SiO 2 coating layer has poor compatibility with the bonding resin, so that the dispersibility or the bonding effect is poor, and the density and the application performance of the finally sintered magnetic powder are affected.
Patent CN 115798854A discloses a preparation method of a low-chromium rust-proof ferrosilicon chromium magnetic powder core, firstly adopting a diluent and a passivating agent to passivate ferrosilicon chromium alloy powder, then adopting low-melting-point organic silicon resin and a coupling agent to coat in sequence, then mixing with a binder for granulation, and obtaining the rust-proof ferrosilicon chromium magnetic powder core after heat treatment. However, the coating effect of the low-melting-point organic silicon resin on the alloy powder is poor, a fluidized bed heating coating process is needed, the low-melting-point organic silicon resin is used as a vaporization coating agent for coating, and the treatment process is complex.
In addition, the binder adopted by the existing magnetic powder core before heat treatment is generally an organic binder such as epoxy resin, and the like, and the binder mainly generates volatile CO 2 gas in the subsequent high-temperature sintering process, so that the density of the material is reduced, and the corrosion resistance and the magnetic property of the magnetic powder core are adversely affected.
Disclosure of Invention
Aiming at the defects and shortcomings of the prior art, the primary purpose of the invention is to provide a preparation method of a corrosion-resistant iron-silicon-chromium alloy soft magnetic material. According to the preparation method, the MQ silicon resin and the crosslinked polysiloxane are adopted to carry out double coating modification on the alloy powder, and the MQ silicon resin and the crosslinked polysiloxane coating have better flexibility than a SiO 2 coating of silica sol, and have the advantages of good coating effect and stable coating. And the obtained alloy powder is directly formed by cross-linking, solidifying and bonding of polysiloxane, and mainly generates insulating and corrosion-resistant SiO 2 in the subsequent sintering process, so that the generation of volatile CO 2 gas is effectively reduced, the density of the material is improved, and the corrosion resistance and magnetic performance of the material can be effectively improved.
The invention also aims to provide the corrosion-resistant iron-silicon-chromium alloy soft magnetic material prepared by the method.
The invention aims at realizing the following technical scheme:
A preparation method of a corrosion-resistant iron-silicon-chromium alloy soft magnetic material comprises the following preparation steps:
(1) Adding ferrosilicon chromium alloy powder into a solvent to be uniformly dispersed, then adding sodium silicate or silicate ester and a vinyl end-capping agent, stirring and uniformly mixing, and adding an acid catalyst under the stirring condition to carry out polymerization equilibrium reaction; after the reaction is finished, filtering, washing and drying are carried out to obtain vinyl MQ silicon resin coated alloy powder;
(2) Uniformly mixing the vinyl MQ silicon resin coated alloy powder obtained in the step (1), hydrogen-containing silicone oil and a catalyst, performing hot pressing, curing and forming, and sintering to obtain the corrosion-resistant iron-silicon-chromium alloy soft magnetic material.
Preferably, the ferrosilicon-chromium alloy powder in the step (1) comprises the following elements in percentage by mass: 3-6% of silicon, 3-6% of chromium and the balance of iron.
Preferably, the average particle size D50 of the ferrosilicon chromium alloy powder in step (1) is 2 to 20 μm.
Preferably, the solvent in the step (1) is at least one of ethanol and isopropanol.
Preferably, the silicate in the step (1) is at least one of ethyl orthosilicate, methyl orthosilicate and isopropyl orthosilicate.
Preferably, the vinyl capping agent in step (1) is tetramethyl divinyl disiloxane.
Preferably, the acid catalyst in step (1) is hydrochloric acid or sulfuric acid; the temperature of the polymerization equilibrium reaction is 30-60 ℃ and the time is 2-6 h.
Preferably, the ferrosilicon chromium alloy powder, the solvent, the sodium silicate or the silicate and the vinyl end capping agent in the step (1) are added in a mass ratio of 100:100-200:10-25:4-8.
Preferably, the hydrogen-containing silicone oil in the step (2) has a hydrogen content of 0.1-1.0% and a weight average molecular weight of 5000-50000 g/mol; the addition amount of the hydrogen-containing silicone oil is 1-10% of the mass of the vinyl MQ silicone resin coated alloy powder.
Preferably, the catalyst in step (2) is a platinum complex catalyst of diethylene tetramethyl disiloxane.
Preferably, the temperature of the hot press curing molding in the step (2) is 50-100 ℃ and the pressure is 500-800 MPa.
Preferably, the sintering temperature in the step (2) is 600-900 ℃ and the sintering time is 10-120 min.
The corrosion-resistant iron-silicon-chromium alloy soft magnetic material is prepared by the method.
The principle of the invention is as follows: firstly, carrying out polymerization equilibrium reaction on sodium silicate or silicate ester and vinyl end capping agent under the condition of acid catalyst, carrying out surface coupling reaction on sodium silicate or silicate ester and ferrosilicon chromium alloy powder in the primary hydrolysis process, and carrying out in-situ coating on ferrosilicon chromium alloy powder dispersed in a solvent by vinyl MQ silicon resin gel generated in the equilibrium reaction process to obtain vinyl MQ silicon resin coated alloy powder. And then mixing the obtained vinyl MQ silicon resin coated alloy powder with hydrogen-containing silicone oil for reaction, and carrying out hydrosilylation crosslinking reaction on vinyl on the surface of the vinyl MQ silicon resin coated alloy powder and Si-H bonds of the hydrogen-containing silicone oil under the conditions of a catalyst and heating, so that the alloy powder is solidified, bonded and molded, and finally, the double SiO 2 coated ferrosilicon chromium alloy soft magnetic material is obtained through sintering, and the corrosion resistance and magnetic property of the alloy soft magnetic material can be obviously improved.
Compared with the prior art, the invention has the beneficial effects that:
(1) According to the preparation method, the MQ silicon resin and the crosslinked polysiloxane are adopted to carry out double coating modification on the alloy powder, and the MQ silicon resin and the crosslinked polysiloxane coating have better flexibility than a SiO 2 coating of silica sol, have the advantages of good coating effect and stable coating, and obviously improve the comprehensive performance of the alloy powder.
(2) The alloy powder is directly formed by cross-linking, solidifying and bonding of polysiloxane, and does not need to adopt adhesives such as epoxy resin, so that SiO 2 with insulation and corrosion resistance is mainly generated in the subsequent sintering process, the generation of volatile CO 2 gas is effectively reduced, the density of the material is improved, and the corrosion resistance and magnetic performance of the material can be effectively improved.
Detailed Description
The present invention will be described in further detail with reference to examples, but embodiments of the present invention are not limited thereto.
Example 1
(1) 100G of iron-silicon-chromium alloy powder (90 wt% of iron, 5wt% of silicon and 5wt% of chromium) with the average particle size D50 of 5.4 mu m is added into 150g of ethanol solvent for uniform dispersion, then 15g of sodium silicate and 6g of tetramethyl divinyl disiloxane are added for uniform stirring and mixing, the temperature is raised to 50 ℃, and 10g of 5mol/L hydrochloric acid catalyst solution is added under the stirring condition for polymerization equilibrium reaction for 4 hours; and after the reaction is finished, filtering, washing and drying to obtain the vinyl MQ silicon resin coated alloy powder.
(2) Uniformly mixing the vinyl MQ silicone resin coated alloy powder obtained in the step (1) with hydrogen-containing silicone oil with the hydrogen content of 0.35% and the weight average molecular weight of 18000g/mol (the adding amount of the hydrogen-containing silicone oil is 5% of the mass of the vinyl MQ silicone resin coated alloy powder) and a catalytic amount of a diethylene tetramethyl disiloxane platinum complex catalyst, performing hot pressing curing molding at 70 ℃ and 800MPa, heating to 800 ℃, and performing heat preservation and sintering for 60min to obtain the corrosion-resistant iron-silicon-chromium alloy soft magnetic material.
Example 2
(1) Adding 100g of iron-silicon-chromium alloy powder (91 wt% of iron, 3wt% of silicon and 6wt% of chromium) with the average particle size D50 of 4.5 mu m into 100g of ethanol solvent for uniform dispersion, then adding 10g of tetraethyl orthosilicate and 4g of tetramethyl divinyl disiloxane, stirring and mixing uniformly, heating to 60 ℃, adding 20g of 5mol/L hydrochloric acid catalyst solution under stirring, and carrying out polymerization equilibrium reaction for 3h; and after the reaction is finished, filtering, washing and drying to obtain the vinyl MQ silicon resin coated alloy powder.
(2) Mixing the vinyl MQ silicone resin coated alloy powder obtained in the step (1) with hydrogen-containing silicone oil with the hydrogen content of 0.60 percent and the weight average molecular weight of 9000g/mol (the adding amount of the hydrogen-containing silicone oil is 10 percent of the mass of the vinyl MQ silicone resin coated alloy powder) and a catalytic amount of a diethylene tetramethyl disiloxane platinum complex catalyst uniformly, performing hot pressing curing molding at 80 ℃ and 500MPa, heating to 900 ℃, and performing heat preservation and sintering for 60 minutes to obtain the corrosion-resistant iron-silicon-chromium alloy soft magnetic material.
Example 3
(1) 100G of iron-silicon-chromium alloy powder (91 wt% of iron, 6wt% of silicon and 3wt% of chromium) with the average particle size D50 of 4.0 mu m is added into 200g of ethanol solvent for uniform dispersion, then 25g of tetramethyl orthosilicate and 8g of tetramethyl divinyl disiloxane are added for uniform stirring and mixing, the temperature is raised to 50 ℃, and 30g of 5mol/L hydrochloric acid catalyst solution is added under the stirring condition for polymerization equilibrium reaction for 4 hours; and after the reaction is finished, filtering, washing and drying to obtain the vinyl MQ silicon resin coated alloy powder.
(2) Uniformly mixing the vinyl MQ silicone resin coated alloy powder obtained in the step (1) with hydrogen-containing silicone oil with the hydrogen content of 0.46% and the weight average molecular weight of 12000g/mol (the adding amount of the hydrogen-containing silicone oil is 1% of the mass of the vinyl MQ silicone resin coated alloy powder) and a catalytic amount of a diethylene tetramethyl disiloxane platinum complex catalyst, performing hot pressing curing molding at 90 ℃ and 700MPa, heating to 700 ℃, and performing heat preservation and sintering for 60min to obtain the corrosion-resistant iron-silicon-chromium alloy soft magnetic material.
Comparative example 1
Compared with the example 1, the comparative example adopts silica sol to replace vinyl MQ silicone resin to coat alloy powder, adopts epoxy resin as a binder, and has the same rest, and the specific preparation steps are as follows:
(1) Adding 100g of iron-silicon-chromium alloy powder (90 wt% of iron, 5wt% of silicon and 5wt% of chromium) with the average particle size D50 of 5.4 mu m into 150g of ethanol solvent, dispersing uniformly, adding 21g of silica sol, stirring and mixing uniformly, heating to 50 ℃, adding 10g of 5mol/L hydrochloric acid catalyst solution under stirring, and carrying out polymerization equilibrium reaction for 4h; and after the reaction is finished, filtering, washing and drying to obtain the silicon dioxide coated alloy powder.
(2) Mixing the silicon dioxide coated alloy powder obtained in the step (1) with an epoxy resin binder solution (the mass fraction is 30% of acetone solution, and the addition amount of epoxy resin is 5% of the mass of the silicon dioxide coated alloy powder), granulating, hot-pressing, solidifying and forming the obtained granulated powder at the temperature of 70 ℃ and the pressure of 800MPa, and then heating to the temperature of 800 ℃ for heat preservation and sintering for 60min to obtain the iron-silicon-chromium alloy soft magnetic material of the comparative example.
Comparative example 2
Compared with the example 1, the comparative example adopts epoxy resin binder to replace hydrogen-containing silicone oil to crosslink and solidify bonding alloy powder, and the rest is the same, and the specific preparation steps are as follows:
(1) 100g of iron-silicon-chromium alloy powder (90 wt% of iron, 5wt% of silicon and 5wt% of chromium) with the average particle size D50 of 5.4 mu m is added into 150g of ethanol solvent for uniform dispersion, then 15g of sodium silicate and 6g of tetramethyl divinyl disiloxane are added for uniform stirring and mixing, the temperature is raised to 50 ℃, and 10g of 5mol/L hydrochloric acid catalyst solution is added under the stirring condition for polymerization equilibrium reaction for 4 hours; and after the reaction is finished, filtering, washing and drying to obtain the vinyl MQ silicon resin coated alloy powder.
(2) Mixing the vinyl MQ silicon resin coated alloy powder obtained in the step (1) with an epoxy resin binder solution (an acetone solution with the mass fraction of 30%, wherein the addition amount of the epoxy resin is 5% of the mass of the vinyl MQ silicon resin coated alloy powder), granulating, hot-pressing and solidifying the obtained granulated powder at the temperature of 70 ℃ and the pressure of 800MPa, and then heating to the temperature of 800 ℃ for 60 minutes, and carrying out heat preservation and sintering to obtain the Fe-Si-Cr alloy soft magnetic material of the comparative example.
The iron-silicon-chromium alloy soft magnetic materials obtained in the above examples and comparative examples were tested for magnetic permeability (test using a precision electromagnetic analyzer 3260B at a test frequency of 10 MHz), insulation resistance (test using a volume surface resistivity tester), loss (FE-2100 SA soft magnetic high frequency BH tester), corrosion resistance (salt spray test, GB/T10125-2021) and density (archimedes' drainage density tester), and the test results are shown in table 1 below.
TABLE 1
As can be seen from the results of comparative example 1 in Table 1, the invention adopts MQ silicone resin and cross-linked polysiloxane to carry out double coating modification on alloy powder, thus being capable of obviously improving the insulation performance and corrosion resistance of the obtained alloy soft magnetic material, effectively reducing magnetic loss and obviously improving the compactness of the material. As can be seen from the result of comparative example 2, the use of polysiloxane crosslinked cured bonding alloy powder can further improve insulation properties, corrosion resistance and compactness and effectively reduce magnetic loss compared with conventional epoxy resin binders. The method is characterized in that compared with the conventional epoxy resin binder, polysiloxane is adopted to crosslink and solidify bonding alloy powder to mainly generate insulating and corrosion-resistant SiO 2 in the subsequent sintering process, so that the generation of volatile CO 2 gas is effectively reduced, the compactness of the material is improved, and the corrosion resistance and magnetic performance of the material are effectively improved.
The above examples are preferred embodiments of the present invention, but the embodiments of the present invention are not limited to the above examples, and any other changes, modifications, substitutions, combinations, and simplifications that do not depart from the spirit and principle of the present invention should be made in the equivalent manner, and the embodiments are included in the protection scope of the present invention.

Claims (10)

1. The preparation method of the corrosion-resistant iron-silicon-chromium alloy soft magnetic material is characterized by comprising the following preparation steps:
(1) Adding ferrosilicon chromium alloy powder into a solvent to be uniformly dispersed, then adding sodium silicate or silicate ester and a vinyl end-capping agent, stirring and uniformly mixing, and adding an acid catalyst under the stirring condition to carry out polymerization equilibrium reaction; after the reaction is finished, filtering, washing and drying are carried out to obtain vinyl MQ silicon resin coated alloy powder;
(2) Uniformly mixing the vinyl MQ silicon resin coated alloy powder obtained in the step (1), hydrogen-containing silicone oil and a catalyst, performing hot pressing, curing and forming, and sintering to obtain the corrosion-resistant iron-silicon-chromium alloy soft magnetic material.
2. The method for preparing the corrosion-resistant ferrosilicon-chromium alloy soft magnetic material according to claim 1, wherein the ferrosilicon-chromium alloy powder in the step (1) comprises the following elements in percentage by mass: 3-6% of silicon, 3-6% of chromium and the balance of iron; the average particle size D50 of the ferrosilicon chromium alloy powder is 2-20 mu m.
3. The method for preparing the corrosion-resistant ferrosilicon-chromium alloy soft magnetic material according to claim 1, wherein the solvent in the step (1) is at least one of ethanol and isopropanol.
4. The method for preparing the corrosion-resistant ferrosilicon-chromium alloy soft magnetic material according to claim 1, wherein the silicate in the step (1) is at least one of ethyl orthosilicate, methyl orthosilicate and isopropyl orthosilicate; the vinyl end-capping agent is tetramethyl divinyl disiloxane.
5. The method for preparing the corrosion-resistant ferrosilicon-chromium alloy soft magnetic material according to claim 1, wherein the acid catalyst in the step (1) is hydrochloric acid or sulfuric acid; the temperature of the polymerization equilibrium reaction is 30-60 ℃ and the time is 2-6 h.
6. The method for preparing the corrosion-resistant ferrosilicon-chromium alloy soft magnetic material according to claim 1, wherein the mass ratio of the ferrosilicon-chromium alloy powder, the solvent, the sodium silicate or the silicate and the vinyl end capping agent added in the step (1) is 100:100-200:10-25:4-8.
7. The method for preparing the corrosion-resistant ferrosilicon chromium alloy soft magnetic material according to claim 1, wherein the hydrogen-containing silicone oil in the step (2) is hydrogen-containing silicone oil with the hydrogen content of 0.1-1.0% and the weight average molecular weight of 5000-50000 g/mol; the addition amount of the hydrogen-containing silicone oil is 1-10% of the mass of the vinyl MQ silicone resin coated alloy powder.
8. The method for preparing the corrosion-resistant ferrosilicon-chromium alloy soft magnetic material according to claim 1, wherein the catalyst in the step (2) is a divinyl tetramethyl disiloxane platinum complex catalyst; the temperature of the hot press solidification forming is 50-100 ℃ and the pressure is 500-800 MPa.
9. The method for preparing the corrosion-resistant ferrosilicon-chromium alloy soft magnetic material according to claim 1, wherein the sintering temperature in the step (2) is 600-900 ℃ and the sintering time is 10-120 min.
10. A corrosion resistant ferrosilicon chromium alloy soft magnetic material, characterized in that it is prepared by the method of any one of claims 1 to 9.
CN202311861097.0A 2023-12-31 2023-12-31 Corrosion-resistant iron-silicon-chromium alloy soft magnetic material and preparation method thereof Active CN117790103B (en)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107578872A (en) * 2017-08-10 2018-01-12 深圳市铂科新材料股份有限公司 A kind of preparation method of the metal soft magnetic powder core of high temperature heat-resistant processing
CN112846196A (en) * 2020-12-31 2021-05-28 莱芜职业技术学院 Preparation method for preparing flaky iron-silicon-chromium soft magnetic composite material
CN113096906A (en) * 2021-03-24 2021-07-09 华南理工大学 FeSiCr alloy magnetic powder with double coating layers and preparation method thereof, magnetic powder core and preparation method thereof
CN113380487A (en) * 2021-05-25 2021-09-10 合泰盟方电子(深圳)股份有限公司 Magnetic core powder for integrally formed inductor and preparation method thereof
CN116779270A (en) * 2023-08-18 2023-09-19 江西悦安新材料股份有限公司 Pressure-resistant high-impedance iron-silicon-chromium magnetic powder core and preparation method thereof

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107578872A (en) * 2017-08-10 2018-01-12 深圳市铂科新材料股份有限公司 A kind of preparation method of the metal soft magnetic powder core of high temperature heat-resistant processing
CN112846196A (en) * 2020-12-31 2021-05-28 莱芜职业技术学院 Preparation method for preparing flaky iron-silicon-chromium soft magnetic composite material
CN113096906A (en) * 2021-03-24 2021-07-09 华南理工大学 FeSiCr alloy magnetic powder with double coating layers and preparation method thereof, magnetic powder core and preparation method thereof
CN113380487A (en) * 2021-05-25 2021-09-10 合泰盟方电子(深圳)股份有限公司 Magnetic core powder for integrally formed inductor and preparation method thereof
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