EP1617443A1 - Bauteil mit verschiedenen magnetischen Eigenschaften und Verfahren dafür - Google Patents

Bauteil mit verschiedenen magnetischen Eigenschaften und Verfahren dafür Download PDF

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Publication number
EP1617443A1
EP1617443A1 EP04076546A EP04076546A EP1617443A1 EP 1617443 A1 EP1617443 A1 EP 1617443A1 EP 04076546 A EP04076546 A EP 04076546A EP 04076546 A EP04076546 A EP 04076546A EP 1617443 A1 EP1617443 A1 EP 1617443A1
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EP
European Patent Office
Prior art keywords
outer ring
inner ring
powdered metal
ring
magnetic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP04076546A
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English (en)
French (fr)
Inventor
David Earl Gay
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Delphi Technologies Inc
Original Assignee
Delphi Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Delphi Technologies Inc filed Critical Delphi Technologies Inc
Priority to EP04076546A priority Critical patent/EP1617443A1/de
Publication of EP1617443A1 publication Critical patent/EP1617443A1/de
Withdrawn legal-status Critical Current

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    • 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
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder

Definitions

  • This disclosure relates to forming items of materials having different properties wherein the desirable properties of the different materials are utilized in different manners while the undesirable qualities of the materials are minimized or nullified.
  • Rotating shafts which are driven by operable machinery provide a means for providing specific data which is related to the rotating shaft or member secured thereto.
  • Sensors to measure the torque imposed on rotating shafts are used in many applications. For example, it might be desirable to measure the torque on rotating shafts in a vehicle's transmission, or in a vehicle's engine (e.g., the crankshaft), or in a vehicle's automatic braking system (ABS) for a variety of purposes known in the art.
  • a vehicle's transmission or in a vehicle's engine (e.g., the crankshaft), or in a vehicle's automatic braking system (ABS) for a variety of purposes known in the art.
  • ABS vehicle's automatic braking system
  • powder metallurgy and particularly iron and iron alloy powders, is known for forming magnets, including soft magnetic cores for transformers, inductors, AC and DC motors, generators, and relays.
  • An advantage to using powdered metals is that forming operations, such as compression molding, injection molding and sintering techniques, can be used to form intricate molded part configurations, such as magnetic cores, without the need to perform additional machining and piercing operations. As a result, the formed part is often substantially ready for use immediately after the forming operation.
  • the securement of the magnetic material to the rotating member provides unique obstacles, as the soft magnetic material is not very suitable for welding processes wherein a strong bond is formed between the rotating shaft and the magnetic material being rotated.
  • Soft magnets can be sintered at temperatures of about 2050 degrees Fahrenheit (about 1120 degrees Celsius) or more to achieve greater mechanical strength.
  • U.S. Patent No. 6,423,264 the contents of which are incorporated herein by reference thereto, such high temperatures affect the magnetic properties of hard or permanent magnetic components.
  • the present disclosure relates to a metallurgy process wherein available that enabled the mass production of rotating electromagnetic components having both a soft outer ring and an inner iron ring for welding to an iron insert or shaft is facilitated.
  • a magnetic armature having an outer ring formed of a first powdered metal, the outer ring having magnetic qualities and the first powdered metal of the outer ring includes metals having poor welding characteristics; an inner ring formed of a second powdered metal and being disposed within the outer ring, the inner ring being an iron metal having good welding characteristics and the inner ring defines an inner opening for receiving a shaft for rotating the magnetic armature; wherein said outer ring and said inner ring are joined together by a sintering process and the shaft is welded to the inner ring.
  • a method of manufacturing an item having magnetic qualities comprising: forming an outer ring of a first powdered metal, the outer ring having magnetic qualities and the first powdered metal of the outer ring comprising metals having poor welding characteristics; forming an inner ring of a second powdered metal, said inner ring being configured to be disposed within said outer ring, said inner ring comprising a pure iron metal having good welding characteristics and said inner ring defining an inner opening configured for receiving a shaft for rotating the item; wherein said outer ring and said inner ring are joined together by a sintering process.
  • a method of manufacturing an item having magnetic qualities comprising: forming an outer ring of a first powdered metal, the outer ring having magnetic qualities and the first powdered metal of the outer ring comprising metals having poor welding characteristics; forming an inner ring of a second powdered metal, said inner ring being configured to be disposed within said outer ring, said inner ring comprising a pure iron metal having good welding characteristics and said inner ring defining an inner opening configured for receiving a shaft for rotating the item; wherein said outer ring and said inner ring are joined together by a sintering process comprising: defining a first cavity in a die, said first cavity corresponding to the outer ring; filling the first cavity with the first powdered metal; defining a second cavity in the die, the second cavity corresponding to the inner ring; filling the second cavity with the second powdered metal; and compacting the first and second powdered metals; and heating the first powdered metal and the second powdered metal in excess of 2000 degrees Fahrenheit.
  • the present disclosure is directed to an item and method manufacture wherein at least two discrete materials having different characteristics and qualities are used to produce an item wherein the two discrete materials have characteristics unique to a particular purpose or application each of which is required by the item.
  • the particular item and configuration described below and in the figures provides an example of an item being manufactured by the method of the present disclosure and the present disclosure is not intended to be limited to the particular items and configurations listed below and shown in the attached figures.
  • Armature 10 is a magnetic armature requiring a soft magnetic outer ring for use in a particular application while the center portion of the armature is secured to the shaft that provides a rotational force to armature 10.
  • Armature 10 comprises an outer ring 12, an inner ring 14 and a central opening 16.
  • Central opening 16 is configured to receive a shaft 18, which is fixedly secured in opening 16 by a welding process.
  • the shaft is secured to a device at the other end for rotating the shaft and the armature.
  • the materials of the outer ring and the inner ring are fused to form a unitary structure, with the outer ring being effectively bonded to the inner ring.
  • the shaft may be installed sufficiently early in the manufacturing process so that the inner ring is firmly secured to the shaft by the same operation that fuses the materials of the inner and outer rings.
  • the shaft may be press fit into the central opening formed in the inner ring.
  • an item or armature that comprises a first material having the desired magnetic qualities and a second item having characteristics that are not found in the desired qualities of the first material but are desirable for other performance reasons, such as strength, weldability and lack of a susceptibility to fatigue etc.
  • Si-Fe Silicon Iron
  • Si-Fe is a material that has good magnetic qualities but does not weld well (e.g., securement to other objects) as the Silicon acts like an impurity that adversely affects the welding process.
  • Si-Fe is not as strong as other materials and is more prone to cracks, fatigue problems and/or strength issues.
  • outer ring 12 comprises a material having the required magnetic qualities and inner ring 14 comprises a material having the required strength and weldability. Therefore, inner ring 14 will provide opening 16 into which shaft 18 is secured.
  • outer ring 12 is formed out of a powdered metal that is filled into a mold, compressed and sintered.
  • the powdered metal is prepared in accordance with known methods and technologies, which would be known to those skilled in the related arts.
  • the prepared powder metal is then placed or filled into a die or mold wherein it is compacted or formed into a green compact.
  • the forming process can be either cold forming or pressing or hot forming or pressing wherein any one of the following methods may be used: die pressing, rubber mold pressing, extrusion molding, slip casting, injection molding. It is noted that the present disclosure is not limited to the mentioned methods, which are provided as examples and are not intended to limit the present disclosure.
  • the formed item is then sintered in accordance with known sintering techniques.
  • Inner ring 14 is also formed out of a powdered metal that is filled into a mold, compressed and sintered. Both inner ring 14 and outer ring 12 are filled and pressed into a mold wherein an inner surface portion 20 of outer ring 14 and an outer surface portion 22 of inner ring 12 are in contact with each such that during the sintering process inner ring 12 and outer ring 14 are bonded or secured together. Accordingly, outer ring 12 is sintered to inner ring 14.
  • the two different powder metal materials are double filled and single pressed in accordance with known technologies for forming items out of powdered metal.
  • the powder metal materials may be filled and pressed more or less than described above.
  • the inner powder would be a good welding material like pure iron powder and the outer powder would be a good magnetic material like Si-Fe or Ni-Fe and the two metals are sintered together.
  • the formed item would have a high spin strength suitable for use in a rotary device capable of spinning the item at high revolutions per minute, wherein the high magnetic performance and weld strength would be at least two features desired in the final product.
  • the present disclosure provides a means for manufacturing, forming or producing an item (e.g., armature) having high magnetic performance, high spin strength wherein a Si-Fe material is used and the item (e.g., armature) is welded to a shaft.
  • armature e.g., armature
  • the un-desirable qualities of an armature of wrought Si-Fe stock material being welded to a steel shaft is overcome by a low cost alternative.
  • the two different powder metal materials form a compacted component or green compact as is known in the art and then the two metals would be sintered together and yield good strength.
  • the sintering process is typically 200 to 300 degrees Fahrenheit hotter than a typical welding process thus the sintering provides a greater bond between the two metals and since the outer ring is a "soft" magnetic material the higher temperature does not adversely affect the magnetic qualities of the outer ring. For example, during a sintering process uniform temperatures are attainable for longer periods of time. Also, there is the ability to control the atmosphere in which the sintering process is performed in order to provide a more desirable atmosphere for the sintering process (e.g.. reducing atmosphere and oxides). Also, the sintering process improves the magnetic qualities of the sintered material by controlling the temperature and atmosphere.
  • the time and temperature of the sintering process may vary in accordance with the materials used and the temperatures provided herein are to be used as examples and are not intended to be limiting.
  • Figures 3-5 illustrate an armature wherein an inner opening 16 is provided to provide a means for receiving a shaft member for rotating the armature.
  • a magnetic outer periphery 24 of the armature illustrated in Figures 3-5 can comprise a Ni-Fe or Si-Fe material which has the desirable magnetic qualities.
  • FIG. 6 a cross sectional view of an armature formed using the process of the present disclosure is illustrated.
  • the outer ring is a Ni-Fe or Si-Fe material or equivalent that has the desired magnetic qualities and the inner ring comprises a material that has the desired weldability qualities.
  • the iron to Ni-Fe or Si-Fe interface 26 is provided by the sintering process therefore a strong bond is made between the two materials.
  • the mold used in the powder metal process provides opening 16 wherein the pure iron material of inner ring 14 can be welded to an iron shaft to provide the desired mechanical strength between the two materials.
  • opening 16 is configurable to have desired features illustrated in Figure 4 or no features ( Figure 6), which depend of course on the shape of the die or mold being used during the compaction, pre-sintering and sintering process.
  • Figure 7 illustrates a shaft contemplated for use with the armature illustrated in the Figure 6.
  • shaft 18 also comprises an iron material having good strength and weldability wherein shaft 18 is welded to the inner surface of opening 16 in inner ring 14.
  • Figure 8 is a cross sectional view of the armature of Figure 6 secured to a shaft and disposed within its preferred location wherein the outer periphery of the magnetic armature is rotated proximate to a sensor or means for providing a magnetic field wherein the rotation of armature 10 and its outer ring of magnetic material provides signals in accordance with a desired use.
  • armature 10 can be used in vehicular applications.
  • the method of making the armature is not intended to be limited to only these types of applications.
  • Figure 9 is an enlarged view of an enlarged portion of Figure 8 and illustrates the weld 32 between inner ring 14 and shaft 18. Also, illustrated in Figure 8 are features 34 which are formed on the surface of opening 16 and shaft 18. Features 34 are configured to assist in the insertion of shaft 18 with opening 16 and can also provide areas to receive weld 32. Alternatively, the surface of shaft 18 and opening 16 are provided with a continuous surface.
  • An example of the type of weld is a laser weld or a tungsten inert gas (TIG) weld or equivalents thereof.
  • Figures 10 - 15 represent the embodiment of the disclosure in which both the inner ring 14 and the outer ring 12 are formed of powder metals.
  • Suitable materials for outer ring 12 are "soft" magnet materials such as iron-nickel alloys, cobalt and its alloys, iron-silicon alloys, iron-phosphorus alloys, iron-silicon-aluminum alloys, ferrites and magnetic stainless steel alloys and equivalents thereof.
  • Suitable materials for the inner ring include pure iron and equivalents thereof.
  • a suitable average particle size range for the powders is about 5 to about 1000 micrometers, with a preferred average size being about 100 to 200 micrometers. Of course, the particle size can be larger or smaller than the aforementioned values.
  • the individual particles of the inner and outer powders are blended in with a lubricant that volatizes or bums off during the sintering process. In one example the lubricant is approximately one percent of the materials being sintered. Of course, the lubricant can be used in percentages that are greater or less than the aforementioned values.
  • the inner and outer powders are encapsulated with a polymeric coating material that bums off cleanly during the sintering operation of this disclosure.
  • Suitable coating materials for this purpose include poly(alkylene carbonates), polypropylene oxide (PPO) polymer systems such as NORYL® from General Electric, waxes, low melting polymers, nylons, polyetherimides such as ULTEM® from General Electric, epoxies, phenolics, polyesters and silicones.
  • PPO polypropylene oxide
  • the powders can be admixed with lubricants such as stearates, fluorocarbons, waxes, low-melting polymers and synthetic waxes such as ACRAWAX available from Lonza, Inc.
  • lubricants such as stearates, fluorocarbons, waxes, low-melting polymers and synthetic waxes such as ACRAWAX available from Lonza, Inc.
  • Suitable methods for encapsulating the powders are well known, and include solution blending, wet blending and mechanical mixing techniques, and Wurster-type batch coating processes such as those described in U.S. Pat. Nos. 2,648,609 and 3,253,944.
  • the polymeric coatings and any lubricants burn off, leaving only the fused magnet particles.
  • the percentages of the materials mentioned above may vary in accordance with desired applications.
  • a suitable manufacturing process for an item manufactured in accordance with the teachings of the present disclosure is based on an apparatus and method disclosed in U.S. Patent No. 5,221,503 to Ward et al, the contents of which are incorporated herein by reference thereto.
  • a punch and die apparatus 120 is shown to have a central core rod 122 aligned along a longitudinal axis 124 of a heated die casing 130, which can be used to pre-heat and pre-sinter the materials prior to a more traditional sintering process.
  • the apparatus 120 is configured to produce an armature (e.g., Figure 6) or other item requiring the materials of different qualities.
  • the die casing does not have to be heated and is used only for compacting prior to sintering in an oven or equivalent structure.
  • An annular inner punch 126 is slidably disposed about the core rod 122 while an annular outer punch 128 is slidably disposed between the inner punch element 126 and the heated die casing 130.
  • a pair of powder dispensers 132 and 134 are provided on a die table 136 that is located at an upper end of the die casing 130. The powder dispensers 132 and 134 are loaded with the inner and outer ring powders, respectively, required for the outer ring 12 and inner ring 14.
  • Each dispenser 132 and 134 is adapted to dispense its powder into one of the cavities formed when the inner and outer punches 126 and 128 are retracted, as will be more fully explained below.
  • the die casing 130 and any other component of the apparatus 120 may be vibrated to enhance the filling of the cavities.
  • the inner and outer punches 126 and 128 are initially cycled to their uppermost positions to expel any foreign matter from the die casing 130.
  • the outer punch 128 is then retracted, as shown in Figure 11, to form an outer ring cavity 140 between the heated die casing 130 and the outer diameter of the inner punch 126.
  • the dispenser 132 is then moved from its base position to the cavity 140, and thereafter fills the cavity 140 with the powder (Ni-Fe or Si-Fe), as indicated in Figure 11.
  • the dispenser 132 then returned to its base position, and the second dispenser 134 is positioned above the punches 126 and 128.
  • the inner punch 126 is then retracted, as seen in Figure 12, to form an inner ring cavity 142, which is immediately backfilled with the pure iron powder from the dispenser 134.
  • the inner ring cavity 142 may be shorter than the outer ring cavity 140 due to differences in the apparent densities of the powders used for the inner and outer rings.
  • the dispenser 134 is returned to its base position as shown in Figure 13, and the inner punch 126 is further retracted to axially center the inner ring cavity 142 within the outer ring cavity 140.
  • a pair of upper punches 144 and 146 are positioned to axially oppose the punches 126 and 128 in preparation for compaction of the powders. As depicted in Figure 14, compaction of the powders is performed by forcing the punches 126 and 128 and opposing punches 144 and 146 toward each other.
  • the die casing 130 is pre-heated to a suitable temperature wherein the polymeric coating materials of the compacted powders begin to fuse, forming a bond between the inner ring and outer ring and the powders comprising thereof.
  • upper punches 144 and 146 can be raised after the compaction step, and the inner and outer punches are raised to eject the green preformed item out of the punch and die apparatus prior to its inclusion into a furnace for sintering.
  • the desired temperatures of the heated die casing depends on the glass transition temperature of the polymers used.
  • the core rod defines central opening 16, and the manufacture of the item is completed with the insertion of the shaft through the opening to yield the armature of Figure 6.
  • the core rod could be lowered to define another cavity corresponding to the opening, and then the shaft inserted in the third cavity so that the powder material is compacted around the shaft.
  • the assembly undergoes the sintering operation.
  • Suitable temperatures for the sintering operation are higher than the temperature at which the magnetic properties of permanent magnet material degrades as the present disclosure is related to an outer ring of a "soft magnetic material".
  • the sintering process is performed at 2050° F. (about 1120° Celsius or more).
  • the sintering process is contemplated to be performed at temperatures greater or less than the aforementioned values and times.
  • the powders are mixed with approximately equal amounts of the same lubricant, and then compacted at a temperature of about 175° Celsius and with a pressing force of about 50 tons per square inch (50 tsi, approximately 770 MPa).
  • the sintering process is contemplated to be performed at temperatures and pressing forces greater or less than the aforementioned values and times.
  • the materials can be compacted used cold forming techniques wherein no extraneous heat is applied.
  • the inner ring would comprise a pure iron section or insert of wrought or pre-molded powdered metal material and the outer ring comprising the Si-Fe or Ni-Fe powder would be filled around the insert and pressed and then the two materials would be sintered together.
  • the inner ring comprises a powdered pure iron section and outer ring is a wrought or pre-molded powdered metal material and then the two materials are sintered together.
  • the inner ring and outer ring both wrought or premolded and then the two pre-made pieces are then sintered together.
  • the inner ring and outer ring are either sintered together along with the shaft or the inner ring is sintered to the shaft and then the outer ring is sintered to the inner ring.
  • any one of the aforementioned combinations are contemplated for use each other alone or in combination thereof in accordance with the present disclosure.
  • the present disclosure describes particular methods for forming an armature having various magnetic characteristics and other qualities, the present disclosure and methods of making are not limited to the specific items or armature disclosed herein but are applicable to numerous other applications wherein an item is desired requiring an inner material and an outer material each having various characteristics suitable to a desired use.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Powder Metallurgy (AREA)
EP04076546A 2004-05-24 2004-05-24 Bauteil mit verschiedenen magnetischen Eigenschaften und Verfahren dafür Withdrawn EP1617443A1 (de)

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EP04076546A EP1617443A1 (de) 2004-05-24 2004-05-24 Bauteil mit verschiedenen magnetischen Eigenschaften und Verfahren dafür

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EP04076546A EP1617443A1 (de) 2004-05-24 2004-05-24 Bauteil mit verschiedenen magnetischen Eigenschaften und Verfahren dafür

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107464651A (zh) * 2016-06-29 2017-12-12 南安市达腾商务服务有限公司 一种笔式汽车点火线圈铁芯的制备工艺

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6423264B1 (en) * 1999-10-14 2002-07-23 Delphi Technologies, Inc. Process for forming rotating electromagnets having soft and hard magnetic components
EP1224989A2 (de) * 2001-01-19 2002-07-24 Delphi Technologies, Inc. Verbundmetallpulverzusammensetzung
US20020196115A1 (en) * 2001-06-12 2002-12-26 Shin-Etsu Chemical Co., Ltd. Magnet and magnetic sensor

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6423264B1 (en) * 1999-10-14 2002-07-23 Delphi Technologies, Inc. Process for forming rotating electromagnets having soft and hard magnetic components
EP1224989A2 (de) * 2001-01-19 2002-07-24 Delphi Technologies, Inc. Verbundmetallpulverzusammensetzung
US20020196115A1 (en) * 2001-06-12 2002-12-26 Shin-Etsu Chemical Co., Ltd. Magnet and magnetic sensor

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107464651A (zh) * 2016-06-29 2017-12-12 南安市达腾商务服务有限公司 一种笔式汽车点火线圈铁芯的制备工艺
CN107464651B (zh) * 2016-06-29 2019-05-10 浙江辉波蕾汽车部件有限公司 一种笔式汽车点火线圈铁芯的制备工艺

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