EP1700319A1 - Powder composition, method for making soft magnetic components and soft magnetic composite component. - Google Patents
Powder composition, method for making soft magnetic components and soft magnetic composite component.Info
- Publication number
- EP1700319A1 EP1700319A1 EP04809049A EP04809049A EP1700319A1 EP 1700319 A1 EP1700319 A1 EP 1700319A1 EP 04809049 A EP04809049 A EP 04809049A EP 04809049 A EP04809049 A EP 04809049A EP 1700319 A1 EP1700319 A1 EP 1700319A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- iron
- soft magnetic
- powder
- composition according
- heat treatment
- 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.)
- Granted
Links
- 239000000843 powder Substances 0.000 title claims abstract description 84
- 239000000203 mixture Substances 0.000 title claims abstract description 44
- 238000000034 method Methods 0.000 title claims abstract description 30
- 239000002131 composite material Substances 0.000 title claims abstract description 14
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 67
- 239000000314 lubricant Substances 0.000 claims abstract description 42
- 239000002245 particle Substances 0.000 claims abstract description 39
- 229910052742 iron Inorganic materials 0.000 claims abstract description 30
- 235000014113 dietary fatty acids Nutrition 0.000 claims abstract description 18
- 229930195729 fatty acid Natural products 0.000 claims abstract description 18
- 239000000194 fatty acid Substances 0.000 claims abstract description 18
- 150000004665 fatty acids Chemical class 0.000 claims abstract description 18
- 125000004432 carbon atom Chemical group C* 0.000 claims abstract description 6
- 239000000696 magnetic material Substances 0.000 claims abstract description 6
- 229920000265 Polyparaphenylene Polymers 0.000 claims abstract 2
- -1 polyphenylene Polymers 0.000 claims abstract 2
- 238000010438 heat treatment Methods 0.000 claims description 26
- LYRFLYHAGKPMFH-UHFFFAOYSA-N octadecanamide Chemical compound CCCCCCCCCCCCCCCCCC(N)=O LYRFLYHAGKPMFH-UHFFFAOYSA-N 0.000 claims description 23
- 230000035699 permeability Effects 0.000 claims description 22
- 239000004734 Polyphenylene sulfide Substances 0.000 claims description 21
- 229920000069 polyphenylene sulfide Polymers 0.000 claims description 21
- 238000005056 compaction Methods 0.000 claims description 20
- 239000012298 atmosphere Substances 0.000 claims description 6
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 5
- 239000001301 oxygen Substances 0.000 claims description 5
- 229910052760 oxygen Inorganic materials 0.000 claims description 5
- 150000001408 amides Chemical class 0.000 claims description 4
- 150000003140 primary amides Chemical class 0.000 claims description 4
- ORAWFNKFUWGRJG-UHFFFAOYSA-N Docosanamide Chemical compound CCCCCCCCCCCCCCCCCCCCCC(N)=O ORAWFNKFUWGRJG-UHFFFAOYSA-N 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 3
- 229920006395 saturated elastomer Polymers 0.000 claims description 3
- HSEMFIZWXHQJAE-UHFFFAOYSA-N hexadecanamide Chemical compound CCCCCCCCCCCCCCCC(N)=O HSEMFIZWXHQJAE-UHFFFAOYSA-N 0.000 claims description 2
- 229910010272 inorganic material Inorganic materials 0.000 claims description 2
- 239000011147 inorganic material Substances 0.000 claims description 2
- WRIDQFICGBMAFQ-UHFFFAOYSA-N (E)-8-Octadecenoic acid Natural products CCCCCCCCCC=CCCCCCCC(O)=O WRIDQFICGBMAFQ-UHFFFAOYSA-N 0.000 claims 1
- LQJBNNIYVWPHFW-UHFFFAOYSA-N 20:1omega9c fatty acid Natural products CCCCCCCCCCC=CCCCCCCCC(O)=O LQJBNNIYVWPHFW-UHFFFAOYSA-N 0.000 claims 1
- QSBYPNXLFMSGKH-UHFFFAOYSA-N 9-Heptadecensaeure Natural products CCCCCCCC=CCCCCCCCC(O)=O QSBYPNXLFMSGKH-UHFFFAOYSA-N 0.000 claims 1
- ZQPPMHVWECSIRJ-UHFFFAOYSA-N Oleic acid Natural products CCCCCCCCC=CCCCCCCCC(O)=O ZQPPMHVWECSIRJ-UHFFFAOYSA-N 0.000 claims 1
- 239000005642 Oleic acid Substances 0.000 claims 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims 1
- QXJSBBXBKPUZAA-UHFFFAOYSA-N isooleic acid Natural products CCCCCCCC=CCCCCCCCCC(O)=O QXJSBBXBKPUZAA-UHFFFAOYSA-N 0.000 claims 1
- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid Chemical compound CCCCCCCC\C=C/CCCCCCCC(O)=O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 claims 1
- 229910052698 phosphorus Inorganic materials 0.000 claims 1
- 239000011574 phosphorus Substances 0.000 claims 1
- 239000011230 binding agent Substances 0.000 abstract description 4
- 238000002360 preparation method Methods 0.000 abstract description 3
- 229920001169 thermoplastic Polymers 0.000 abstract description 2
- 239000004416 thermosoftening plastic Substances 0.000 abstract description 2
- UCKMPCXJQFINFW-UHFFFAOYSA-N Sulphide Chemical compound [S-2] UCKMPCXJQFINFW-UHFFFAOYSA-N 0.000 abstract 1
- 239000000306 component Substances 0.000 description 40
- 239000011162 core material Substances 0.000 description 12
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 8
- 235000021355 Stearic acid Nutrition 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 7
- 229940037312 stearamide Drugs 0.000 description 7
- 239000008117 stearic acid Substances 0.000 description 7
- 238000009826 distribution Methods 0.000 description 6
- RKISUIUJZGSLEV-UHFFFAOYSA-N n-[2-(octadecanoylamino)ethyl]octadecanamide Chemical compound CCCCCCCCCCCCCCCCCC(=O)NCCNC(=O)CCCCCCCCCCCCCCCCC RKISUIUJZGSLEV-UHFFFAOYSA-N 0.000 description 6
- 239000011248 coating agent Substances 0.000 description 5
- 238000000576 coating method Methods 0.000 description 5
- 239000008358 core component Substances 0.000 description 5
- 230000004907 flux Effects 0.000 description 4
- 230000006698 induction Effects 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 3
- 238000009413 insulation Methods 0.000 description 3
- 239000007858 starting material Substances 0.000 description 3
- 229920005992 thermoplastic resin Polymers 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 239000004610 Internal Lubricant Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 238000000748 compression moulding Methods 0.000 description 2
- 238000007723 die pressing method Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000010419 fine particle Substances 0.000 description 2
- 239000011261 inert gas Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 230000001050 lubricating effect Effects 0.000 description 2
- 239000006247 magnetic powder Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- FATBGEAMYMYZAF-KTKRTIGZSA-N oleamide Chemical compound CCCCCCCC\C=C/CCCCCCCC(N)=O FATBGEAMYMYZAF-KTKRTIGZSA-N 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 241000269627 Amphiuma means Species 0.000 description 1
- 235000019484 Rapeseed oil Nutrition 0.000 description 1
- 208000036366 Sensation of pressure Diseases 0.000 description 1
- 239000003677 Sheet moulding compound Substances 0.000 description 1
- 229910001315 Tool steel Inorganic materials 0.000 description 1
- AFCIMSXHQSIHQW-UHFFFAOYSA-N [O].[P] Chemical compound [O].[P] AFCIMSXHQSIHQW-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000011362 coarse particle Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010292 electrical insulation Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000005461 lubrication Methods 0.000 description 1
- 239000006249 magnetic particle Substances 0.000 description 1
- 150000004702 methyl esters Chemical class 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000012299 nitrogen atmosphere Substances 0.000 description 1
- 229960003903 oxygen Drugs 0.000 description 1
- 125000003703 phosphorus containing inorganic group Chemical group 0.000 description 1
- 238000013001 point bending Methods 0.000 description 1
- 230000008092 positive effect Effects 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 150000004671 saturated fatty acids Chemical class 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 229920006013 termoplastic resin Polymers 0.000 description 1
- 150000004670 unsaturated fatty acids Chemical class 0.000 description 1
- 235000021122 unsaturated fatty acids Nutrition 0.000 description 1
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 1
Classifications
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- 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
-
- 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
- H01F1/20—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 in the form of particles, e.g. powder
- H01F1/22—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 in the form of particles, e.g. powder pressed, sintered, or bound together
- H01F1/24—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 in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
- H01F1/26—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 in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated by macromolecular organic substances
-
- 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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
-
- 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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/05—Metallic powder characterised by the size or surface area of the particles
-
- 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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
-
- 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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/16—Metallic particles coated with a non-metal
-
- 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
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
- B22F3/14—Both compacting and sintering simultaneously
-
- 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
-
- 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
- H01F1/032—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 hard-magnetic materials
-
- 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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/105—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing inorganic lubricating or binding agents, e.g. metal salts
-
- 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
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F2003/248—Thermal after-treatment
-
- 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
- B22F2009/0828—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 with water
-
- 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
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
-
- 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
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
-
- 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
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
- B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
Definitions
- the present invention relates to iron-based powder compositions. More specifically, the invention concerns powder 5 compositions for producing soft magnetic composite components by the powder metallurgical production route. The compositions facilitates the manufacture of the soft magnetic composite component having high density as well as valuable magnetic and mechanical properties.
- Soft magnetic materials are used for applications, such as core materials in inductors, stators and rotors for electrical machines, actuators, sensors and transformer cores.
- soft magnetic cores such as rotors
- Soft Magnetic Composite, SMC materials are based on soft magnetic particles, usually iron- based, with an electrically insulating coating on each particle.
- the SMC parts are obtained.
- this powder metallurgical technique it is possible to produce materials giving a higher degree of freedom in the design of the SMC
- the magnetic permeability of a material is an indication of its ability to become magnetised or its ability to carry a magnetic flux. Permeability is defined as the ratio of the induced magnetic flux to the magnetising force or field intensity.
- the eddy current loss is brought about by the production of electric currents in the iron core component due to the changing flux caused by alternating current (AC) conditions and is proportional to the square of the frequency of the alternating field.
- a high electrical resistivity is then desirable in order to minimise the eddy currents and is of especial importance at higher frequencies.
- Desired component properties include e.g. a high permeability through an extended frequency range, low core losses, high saturation induction, (high density) and high strength. Normally an increased density of the component enhances all of these properties.
- the desired powder properties include suitability for compression moulding techniques, which i.a. means that the powder can be easily moulded into a high density, high strength component which can be easily ejected from the moulding equipment and that the components have smooth surface finish.
- the present invention concerns a new powder composition having the desired powder properties as well as the use of the powder composition for the preparation of soft magnetic composite components.
- the new composition can be compacted (and heat treated) to components having the de- sired properties.
- the present invention also concerns a method for manufacturing soft magnetic iron-based components having excellent component properties as well as the soft magnetic component per se.
- the powder composition according to the invention is made up by electrically insulated particles of a soft magnetic material and a fatty acid amide lubricant.
- a thermoplastic binder is present in the composition.
- the method according to the present invention includes mixing, compaction and optionally heat treatment of the obtained component resulting in a soft magnetic iron-based component having excellent properties.
- the powder is preferably a substantially pure, water atomised iron powder or a sponge iron powder having irregularly shaped particles.
- the term "sub- stantially pure” means that the powder should be substantially free from inclusions and that the amounts of the impurities 0, C an N should be kept at a minimum.
- the average particle sizes are generally below 300 ⁇ m and above 10 ⁇ m. Examples of such powders are ABC 100.30, ASC 100.29, AT 40.29, ASC 200, ASC 300, NC 100.24, SC 100.26, MH 300, MH 40.28, MH 40.24 available from Hoganas AB, Sweden.
- the powders used have coarser particles than what is normal in common die pressing. In practice this means that the powders are essentially without fine particles.
- the term "essentially without fine particles” is intended to mean that less than about 10%, preferably less than 5% the powder particles have a size below 45 ⁇ m as measured by the method described in SS-EN 24 497.
- the average particle diameter is typically between 106 and 425 ⁇ m.
- the amount of particles above 212 ⁇ m is typically above 20%.
- the maximum particle size may be about 2 mm.
- the size of the iron-based particles normally used within the PM industry is distributed according to a gaussian distribution curve with an average particle diameter in the region of 30 to 100 ⁇ m and about 10-30% of the particles are less than 45 ⁇ m.
- the powders used accord- ing to the present invention may have a particle size distribution deviating from that normally used. These coarse powders may be obtained by removing the finer fractions of the powder or by manufacturing a powder having the desired particle size distribution.
- the invention is however not limited to the coarse powders but also powders having the particle sizes normally used for die pressing within the PM industry are included in the present invention.
- the electrical insulation of the powder particles may be made of an inorganic material. Especially suitable are the type of insulation disclosed in the US 6348265 (which is hereby incorporated by reference) , which concerns particles of a base powder consisting of essentially pure iron having an insulating oxygen- and phosphorus-containing barrier. As regards the coating it should be especially mentioned that the properties of the composite component may be influenced by the thickness of the coating. Powders having insulated particles are available as SomaloyTM 500 and 550 from Hoganas AB, Sweden.
- the lubricant used according to the invention is selected from the group consisting of fatty acid amides.
- Particu- larly suitable amides are primary amides of saturated or unsaturated fatty acid having 12-24, preferably 14-22 C atoms and most preferably 18-22 C atoms.
- the lubricants may be used in amounts less than 2% and preferably less than 1.5% by weight of the composition.
- Especially pre- ferred amounts of the lubricant are 0.05-1%, preferably 0.05-0.8 more preferably 0.1-0.8% and most preferably 0.1-0.5% by weight.
- Especially preferred lubricants are stearic acid amide, oleic acid amide, behenic acid amide, eurcic acid amide, palmitic acid amide, the stearic acid amide being most preferred.
- stearic acid amide seemingly in combination with rapeseed oil methyl ester is mentioned as a lubricant in connec- tion with a termoplastic resin, polyphatala ide as a binder for the compaction of soft magnetic powders.
- Solid lubricants generally have a density of about 1-2 g/cm 3 which is very low in comparison to the density of the iron- based powder, which is about 7.8 g/cm 3 .
- inclusions of these less dense lubricants in the compositions will lower the theoretical density of the compacted component. It is therefore essential to keep the amount of lubricant at low levels in order to produce high-density components.
- low amounts of lubricants tend to give ejection problems. It has now unexpectedly been found that the type of lubricants mentioned above can be used in low amounts without ejection problems .
- the fatty acid amide may be used as the only additive to the insulated iron or iron-based powder, although for certain applications it is advantageous to add minor amounts of a thermoplastic resin, specifically polyphenylene sulfide (PPS) .
- PPS polyphenylene sulfide
- the term "minor amounts" should in this context be interpreted as less than 2, preferably less 0.8, more preferably less than 0.6 and most preferably less than 0.5% by weight of the composition. In amounts lower than 0.05 no effects of PPS have been observed. Specifically the amount of PPS could vary between 0.1 and 0.5 and preferably between 0.2 and 0.5 or 0.4% by weight. The addition of PPS is of particular interest when good frequency stability is required.
- a soft magnetic material can be produced by mixing an electrically insulated iron-based powder with PPS and stearic acid. The mixture is cora- pacted at elevated temperature and the obtained compacted part is heat treated at 260°C in an atmosphere of nitrogen followed by a second heat treatment at 285 to 300°C. It has now unexpectedly been found that by using the new powder composition, which includes a fatty acid amide in stead of a corresponding fatty acid several advantages can be obtained.
- the new powder has unexpectedly improved lubricating properties, which results in that lower ejection energy is needed to eject the compacted part from the die, that higher densi- ties and that better transverse rupture strength can be obtained.
- the compaction step can be performed at ambient temperature.
- the heat treatment can be facilitated, as the first heat-treating step, which is required according to the WO publication, can be omitted.
- Iron-based magnetic powders which have insulated particles and which are combined with thermoplastic resins, are described in the US patent application 2002/0084440. In contrast to the particles according to the present in- vention these previously known particles also include a rare earth element.
- the thermoplastic resin is used in relatively large amounts, namely at least 5% by weight.
- the particle size of the iron- based powder is quite small (3 ⁇ m is mentioned as an exa - pie) .
- a lubricant selected from a wide variety of chemical compounds may also be included. These powder compositions are taught to be useful preferably for injection molding, extrusion, injection compression molding and injection pressing for the preparation of highly weather- resistant bonded permanent magnets.
- the powder composition is first uniaxi- ally pressed in a die, which normally must not be lubricated, although the powder composition may also be used in lubricated dies.
- the compacted component is then ejected from the die and optionally subjected to a heat treatment.
- the compaction may be performed at ambient or elevated temperatures and at pressures up to 1500 MPa.
- the compaction is performed in a moderately heated tool as in this way not only the green density and the ejection behaviour but also the maximum relative permeability will be improved.
- the component compacted at an elevated temperature will have a higher permeability.
- the heat treatment can be performed in one or several steps.
- a recommended one step heat treatment is performed for a period of 30 minutes to 4 hours in an oxy- gen-containing atmosphere (air) at a temperature between 250 and 550°C.
- Another alternative is to perform the heat treatment at 250-350°C for a period of 30 minutes to 3 hours in a air or inert gas followed by a heat treatment for 15 minutes to 2 hours in an oxygen containing (air) atmosphere at a temperature between 350 and 550°C.
- the heat treatment may be performed at 250-350°C for 30 min- utes to 4 hours in an oxygen-containing atmosphere (air) .
- Another alternative is to perform the heat treatment at 250-350°C for 30 minutes to 3 hours in air or inert gas followed by 300-500°C for 15 minutes to 2 hours in an oxygen containing atmosphere (air) .
- Such components may be of interest for the demanding applications required in e.g. stator and rotor components in electrical machines.
- the powder mixes were compacted into ring samples with an inner diameter of 45 mm, outer diameter 55 mm and height 5 mm at 800 MPa at ambient (room) temperature. Ring samples with a height of 10 mm were also compacted and the ejection force was measured on these samples.
- the ejection energy is shown in Table 2. The results show that considerably lower ejection energy is obtained by using the fatty acid amide.
- the relative AC inductance permeability was measured with an LCR-meter (HP4284A) according to standard IEC 60404-6, 2 nd Edition 2003-06.
- the drop in initial permeability is shown in tables 3 and 4.
- the drop in initial permeability is expressed as the difference between the initial permeability at 10 and 100 kHz divided by the initial perme- ability at 10 kHz.
- Table 3 shows that by increasing the amount of the fatty acid amid from 0.3 to 0.5% a better frequency stability can be obtained.
- Table 4 shows that by using the fatty acid amid instead of the corresponding fatty acid a better frequency stability is obtained.
- the base powder SomaloyTM 500 was mixed with PPS and lubricants according to the following table 7.
- Powder mixes Lubricants and PPS, percent by weight .
- the powder mixes were compacted into test bars according to ISO 3995 at a compaction pressure of 800 MPa at ambient temperature. After compaction the parts were heat treated in a two-step heat treatment. The first step was performed at 290°C for 105 minutes in inert nitrogen atmosphere. This step was followed by a subsequent heat treatment step at 350°C for 60 minutes in air. Samples were tested with regard to Transverse Rupture Strength, TRS, according to ISO 3995. Results from testing of transverse rupture strength are shown in table 8. As can be seen from table 8 samples prepared with mixtures including the fatty acid amide give sufficient TRS-values. A higher density after heat treatment is reached, which is beneficial in terms on induction and permeability.
- the obtained mixes were transferred to a die and compacted into cylindrical test samples (50 grams) with a diameter of 25 mm, in an uniaxially press movement at a compaction pressure of 1100 MPa.
- the used die material was conventional tool steel.
- the total ejection energy/enveloping area needed in order to eject the samples was calculated.
- the following table 11 show ejection energy, green density and the surface finish.
- the following example illustrates the effect of the particle size distribution of the soft magnetic iron-based powder on ejection behaviour and green density.
- a "coarse” powder according to example 3 was used.
- the particle size distribution of the "fine” powder is given in table 12.
- the mixes were prepared using 0.2% stearamide by weight according to the procedure in example 3.
- the mixture based on the "fine” powder is marked sample H and were compared with sample C.
- the composition containing fine powder results in a lower green density and deteriorated surface finish.
- This example compares a known lubricant, ethylene bis- stearamide (EBS) , and an example of the lubricant steara- mide.
- EBS ethylene bis- stearamide
- a "coarse" powder according to example 3 was used was mixed with EBS and stearamide, respectively, according to table 14. The samples were prepared according to the procedure in example 3.
- the powder mixes were compacted into rings with an inner diameter of 45 mm, an outer diameter of 55 mm and the height 10 mm at 1100 MPa.
- the total ejection energy/enveloping area needed in order to eject the samples from the die was calculated.
- the following table 15 shows the calculated ejection energy/area, green density and the surface appearance.
- the new lubricant can be added in amount as low as 0.2% and still a perfect surface finish can be obtained whereas the for the reference lubricant, EBS, the lowest addition is 0.4% for obtaining a perfect surface finish.
- This example compares the magnetic properties of components manufactured with a minimum amount of the lubricating components stearamide and EBS respectively, in order to achieve similar values of ejection energy. Components made from mix 2 and mix 6 according to example 5 were compared regarding magnetic properties after heat treatment .
- the green samples were heat treated at 300°C for 60 minutes in air followed by a second step of heat treatment at 530°C for 30 minutes in air.
- the obtained heat-treated rings were wounded with
- the following example shows the influence of die temperature on the ejection properties and green density of compacted samples.
- the primary amide stearamide
- 0.2% of stearamide was added to 2 kg of a coarse soft magnetic electrically insulated iron-based powder according to the procedure of example 3.
- the powder mixes were compacted into rings having an in- ner diameter of 45 mm, an outer diameter of 55 mm and a height of 10 mm, at a compaction pressure of 1100 MPa. During ejection of the compacted samples the ejection forces were recorded. The total ejection energy/enveloping area needed in order to eject the samples from the die was calculated.
- the following table 17 shows ejection energy, green density and the surface appearance of the samples compacted at different temperature of the die .
- This example compares component properties of components manufactured according to the present invention to properties of components compacted with the aid of DWL.
- a "coarse" powder according to example 3 was used.
- As lubricant in the inventive example 0.2% by weight of stearamide was used and the obtained powder composition was compacted at a controlled die temperature of 80°C into ring samples having a green density of 7.6 g/cm 3 .
- no internal lubricant was used, instead DWL was applied. Ring samples were compacted to a density of 7.6 g/cm 3 at ambient temperature.
- the ring samples outer diameter was 55 mm, inner diameter 45 mm and height 5 mm.
- iron-powder cores with excellent magnetic properties can obtained by the present invention.
- the positive effect of elevated die temperature on the maximal relative permeability is also shown.
- the density was determined by measuring the mass and dimensions of the ring samples.
- the specific electrical resistivity was measured by a 4-point method on the ring samples.
- Prior to magnetic measurements in a Brockhaus hysterisisgraph the ring samples were wound with 100 drive and 100 sense turns.
- the DC-properties such as ⁇ max and H c were acquired from a loop at lOkA/m while the core loss was measured at IT and 400Hz.
- TRS transverse rupture strength
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Abstract
Description
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SE0303580A SE0303580D0 (en) | 2003-12-29 | 2003-12-29 | Composition for producing soft magnetic composites by powder metallurgy |
PCT/SE2004/001865 WO2005064621A1 (en) | 2003-12-29 | 2004-12-15 | Powder composition, method for making soft magnetic components and soft magnetic composite component. |
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EP (1) | EP1700319B1 (en) |
JP (2) | JP5138227B2 (en) |
KR (1) | KR100775179B1 (en) |
CN (1) | CN100533610C (en) |
AU (1) | AU2004309770B2 (en) |
BR (1) | BRPI0418274A (en) |
CA (1) | CA2552142C (en) |
DK (1) | DK1700319T3 (en) |
ES (1) | ES2655322T3 (en) |
PL (1) | PL1700319T3 (en) |
RU (1) | RU2326461C2 (en) |
SE (1) | SE0303580D0 (en) |
TW (1) | TWI394178B (en) |
UA (1) | UA78954C2 (en) |
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Cited By (3)
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US11085102B2 (en) | 2011-12-30 | 2021-08-10 | Oerlikon Metco (Us) Inc. | Coating compositions |
US11253957B2 (en) | 2015-09-04 | 2022-02-22 | Oerlikon Metco (Us) Inc. | Chromium free and low-chromium wear resistant alloys |
US11939646B2 (en) | 2018-10-26 | 2024-03-26 | Oerlikon Metco (Us) Inc. | Corrosion and wear resistant nickel based alloys |
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US8475709B2 (en) * | 2007-03-21 | 2013-07-02 | Hoganas Ab (Publ) | Powder metal polymer composites |
JP5363081B2 (en) * | 2008-11-28 | 2013-12-11 | 住友電気工業株式会社 | Metallurgical powder, dust core, metallurgical powder manufacturing method and dust core manufacturing method |
JP5650928B2 (en) * | 2009-06-30 | 2015-01-07 | 住友電気工業株式会社 | SOFT MAGNETIC MATERIAL, MOLDED BODY, DUST CORE, ELECTRONIC COMPONENT, SOFT MAGNETIC MATERIAL MANUFACTURING METHOD, AND DUST CORE MANUFACTURING METHOD |
CA2773441C (en) * | 2009-09-18 | 2018-02-06 | Hoeganaes Ab (Publ) | Ferromagnetic powder composition and method for its production |
RU2469430C1 (en) * | 2011-09-13 | 2012-12-10 | Государственное образовательное учреждение высшего профессионального образования "Южно-Российский государственный технический университет (Новочеркасский политехнический институт)" | Soft magnetic composite material |
DE102013200229B4 (en) * | 2013-01-10 | 2024-06-06 | Robert Bosch Gmbh | Process for producing a soft magnetic composite material |
NL2011129C2 (en) * | 2013-07-09 | 2015-01-12 | Eco Logical Entpr B V | COMPACT ELECTRICAL DEVICE AND ELECTRODYNAMIC LOUDSPEAKER, ELECTRIC MOTOR, SCREENER AND ADJUSTABLE COUPLING BASED ON THEM. |
JP2015070077A (en) * | 2013-09-27 | 2015-04-13 | 住友電気工業株式会社 | Powder-compact magnetic core, producing method thereof, and coil part |
GB201409250D0 (en) * | 2014-05-23 | 2014-07-09 | H Gan S Ab Publ | New product |
JP6423629B2 (en) * | 2014-06-30 | 2018-11-14 | 住友電気工業株式会社 | Powder core and coil parts |
KR101664603B1 (en) * | 2014-11-27 | 2016-10-11 | 현대자동차주식회사 | Powder metallurgical method |
CN105458249A (en) * | 2015-11-26 | 2016-04-06 | 扬州海昌粉末冶金有限公司 | Method for manufacturing high-magnetic-conductivity sintered iron-based soft magnetism product |
JP6882375B2 (en) * | 2019-06-06 | 2021-06-02 | 株式会社神戸製鋼所 | Mixed powder for dust core and powder magnetic core |
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US11253957B2 (en) | 2015-09-04 | 2022-02-22 | Oerlikon Metco (Us) Inc. | Chromium free and low-chromium wear resistant alloys |
US11939646B2 (en) | 2018-10-26 | 2024-03-26 | Oerlikon Metco (Us) Inc. | Corrosion and wear resistant nickel based alloys |
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AU2004309770A1 (en) | 2005-07-14 |
KR20060103539A (en) | 2006-10-02 |
CN1902719A (en) | 2007-01-24 |
TWI394178B (en) | 2013-04-21 |
JP2010028131A (en) | 2010-02-04 |
ZA200605385B (en) | 2007-11-28 |
BRPI0418274A (en) | 2007-05-02 |
SE0303580D0 (en) | 2003-12-29 |
UA78954C2 (en) | 2007-04-25 |
ES2655322T3 (en) | 2018-02-19 |
JP2007535134A (en) | 2007-11-29 |
JP5138227B2 (en) | 2013-02-06 |
PL1700319T3 (en) | 2018-05-30 |
AU2004309770B2 (en) | 2008-05-22 |
TW200534298A (en) | 2005-10-16 |
RU2326461C2 (en) | 2008-06-10 |
EP1700319B1 (en) | 2017-10-18 |
CA2552142A1 (en) | 2005-07-14 |
CA2552142C (en) | 2011-09-20 |
KR100775179B1 (en) | 2007-11-12 |
DK1700319T3 (en) | 2018-01-02 |
WO2005064621A1 (en) | 2005-07-14 |
RU2006127438A (en) | 2008-02-10 |
CN100533610C (en) | 2009-08-26 |
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