EP2289082A1 - Method for producing a magnetizable metal shaped body - Google Patents

Method for producing a magnetizable metal shaped body

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Publication number
EP2289082A1
EP2289082A1 EP09741823A EP09741823A EP2289082A1 EP 2289082 A1 EP2289082 A1 EP 2289082A1 EP 09741823 A EP09741823 A EP 09741823A EP 09741823 A EP09741823 A EP 09741823A EP 2289082 A1 EP2289082 A1 EP 2289082A1
Authority
EP
European Patent Office
Prior art keywords
starting material
particles
surface coating
compression
compaction
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
Application number
EP09741823A
Other languages
German (de)
French (fr)
Other versions
EP2289082B1 (en
Inventor
Paul Gümpel
Stefan GLÄSER
Beat Hofer
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.)
Kennametal Europe GmbH
ETO Magnetic GmbH
Original Assignee
Kennametal HTM AG
ETO Magnetic GmbH
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 Kennametal HTM AG, ETO Magnetic GmbH filed Critical Kennametal HTM AG
Publication of EP2289082A1 publication Critical patent/EP2289082A1/en
Application granted granted Critical
Publication of EP2289082B1 publication Critical patent/EP2289082B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • 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
    • 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
    • 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

Definitions

  • the present invention relates to a method for producing a magnetizable metallic shaped article, a molded article produced by such a method and uses of such a shaped article.
  • magnetizable metallic bodies are known in the prior art for realizing various electromagnetic devices, such as electromagnetic actuators, transformers or the like. All these applications have in common that a material used for the production of the magnetizable components and assemblies on the one hand should have favorable magnetic properties in the form of the highest possible (saturation) flux density at low excitation and low coercive field strength, with pure iron (or materials made of iron or made of iron-silicon alloys) in view of such magnetic properties is particularly favorable.
  • Eddy current losses are also highly frequency-dependent, so that it is also known, for example in high-frequency applications, to increase the specific electrical resistance use powder composite materials of a metal powder, which with a z. B. polymeric binder is pressed.
  • a procedure In addition to the relatively high electrical resistance relative to a sheet such a procedure also has the advantage that eddy currents can be suppressed three-dimensional.
  • the magnetic properties of such powder composites are often insufficient, such as a typical saturation flux density of a metal is 1.5 to about 5 times higher than such plastic bound metal powders.
  • a molded article produced in this way has inadequate mechanical properties, for example in the form of mechanical strength.
  • the object of the present invention is therefore to provide a magnetizable metallic molded body and a method for producing such, on the one hand energetic adverse eddy currents can be effectively suppressed or minimized, on the other hand still favorable magnetic properties, especially high magnetic (saturation -) flux density and low coercive field strength, can be ensured, wherein such a shaped body should also have improved mechanical properties (as compared to known powder or sintered materials). Furthermore, suitable uses for such a method or molded bodies realized thereby are to be created.
  • the invention is based first of all on the knowledge that when eddy currents are already in the micro range (ie in the range of the particle size or particle size of the pulverulent particle) ferromagnetic starting material) are limited, favorable magnetic properties of the resulting molded body can be achieved. Accordingly, the method according to the invention, by pre-compression in the form of the step of first compressing the starting material already allows a (mechanically stable) body by the Formtial.
  • the cavities in accordance with the further development by the introduction of a correspondingly reactive gas are used to form those surface sections of the particles Particles that are located outside of the connecting sections (bridges) to a respective adjacent particle, to be provided with a very thin (relative to the particle size) partial coating.
  • the subsequent second compaction then leads to the cavities being eliminated or greatly reduced so that, as a result, there is a highly compressed particle structure with layer sections of the isolated (surface) coating which, distributed in micro size and in the body, according to the invention effect intended effect of the eddy current barriers in the micro range.
  • the invention makes it possible to produce a magnetizable metallic material as a shaped body, in which (three-dimensionally) electrically non-conductive, thin layer layers (usually only in the nanometer range in the layer thickness) are distributed, which serve as effective eddy current barriers.
  • the shaped body thus produced not only has the desired high magnetic power density (which potentially comes close to pure iron material), also the Eddy current losses significantly reduced by the effect of the three-dimensionally distributed in the body layer sections. This then gives rise to the possibility, for example, of improving the energy efficiency (resource-saving) of electromagnetic units, eg. As actuators to make, with the high flux density realized at low excitation compact devices that save space and bring other benefits.
  • a further advantage of the invention resides in the fact that a shaped body realized according to the invention has outstanding mechanical properties, in particular with regard to stability, tensile strength and breaking strength, in particular over traditionally known materials and material arrangements for minimizing eddy current losses.
  • electromagnetic properties of a molded article made in accordance with the present invention can be achieved that correspond to a typical reference material such as FeSi3, but have significantly improved mechanical properties with respect to this material.
  • the inventive generation of the insulating Oberflachenbe- layering takes place after in the first step of compaction of the starting material adjacent particles to each other via bridging or the like. have been joined together and accordingly cause a favorable basic strength of the body.
  • a oxidizing or nitriding of the particle surfaces outside of the connecting portions (bridges) causing gas wherein such gas may also be a carbon, nitrogen, oxygen, sulfur and / or boron-containing gas. It is also within the scope of the invention to supply such a gas not separately, but to use as reactive gas that (residual) is already present in the powdery starting material and / or formed or formed during the first compression process, wherein in this Case, the step of generating the electrically insulating top flat coating with the first compression takes place.
  • the second compression after the production the insulating surface layering a typically by hot hydrostatic pressing with a significantly higher pressure of up to about 4000 bar performed process.
  • an alternative embodiment of the invention provides for the inventive process to be supplied with powdered particles which themselves act as coated particles, e.g. , Example, iron particles, with (other) metal coating or semiconductor coating, are present (eg by upstream plasma coating).
  • powdered particles which themselves act as coated particles, e.g. , Example, iron particles, with (other) metal coating or semiconductor coating, are present (eg by upstream plasma coating).
  • this makes it possible on the one hand to influence the mechanical connection behavior (for example the quality of the sintered bridges) after the step of the first compacting, on the other hand enables such precoating of the particles to produce favorable insulating surfaces by targeted formation of the reactive gas to be introduced into the pore space (eg B. an aluminum oxide surface coating by oxidation of an aluminum precoated iron particle by means of the coating step).
  • the shaped body in the manner described according to the invention is produced in principle accessible to a large number of magneti ⁇ rule applications, wherein the advantages described above with regard to efficiency, magnetic Verhal ⁇ th, mechanical compactness and stability of each SITUATE can be instrumentalized - so extends the potential range of application of the present invention of magnetic actuators or drive devices (such as electromagnetic actuators and electric motors) on the use in transformers and other areas of power electronics to electromagnetic bearings and tasks of high-frequency technology.
  • magnetic actuators or drive devices such as electromagnetic actuators and electric motors
  • Figure 1 A flow chart with process steps Sl to S7 for carrying out the inventive method according to a first embodiment
  • FIG. 2 a view with a plurality of schematic illustrations, which illustrate the process-related changed shaping of the shaped body or of the particles of the starting material along the steps S 1 to S 6 of FIG. 1.
  • powdered iron raw material of a typical average grain size in the range of about 10 ⁇ m to 500 ⁇ m is provided; the reference numeral 10 illustrate the process step Sl, the presence of such powder particles in the uncoated state.
  • Typical commercial powder materials in view of a comparatively small grain size are e.g. Pure iron powder (Fe2) with grain size ⁇ 30 ⁇ m, D50 (average grain size) 9 ⁇ m to ll ⁇ m of the manufacturer ThyssenKrupp Metallurgie, in the case of a larger grain size is exemplified in the product Ampersint (verduste Fe-base powder from HC Starck GmbH), here the grain size Fe amounts to at least 99.5 (wt)% less than 350 ⁇ m.
  • Alternative Fe base powders of this manufacturer are FeSi3 or FeSi ⁇ with corresponding grain size.
  • Process step S2 as an optional process step provides the possibility that before a subsequent first dense (step S3) the powder particles of the raw material, for example by means of plasma coatings or the like are provided with a metallization or semiconductor coating.
  • This optional layer to be applied in step S2 is thin relative to the respective particle diameter and is typically in the range between 5 and 50 nm.
  • a first precompression of the (coated or uncoated) raw material takes place, typically a cold hydrostatic pressing with a compression pressure of about 1000 bar.
  • the result is the image of a precompressed body illustrated in FIG. 2 (in the case of uncoated raw material), in which the particles 10 are adhered to one another mechanically by means of sintered bridges.
  • step S4 is an oxidizing gas, bar, in this case oxygen, at a pressure of 0.01 and a temperature of 350 0 C as inserted into the Formkör- by that this gas enters the cavities 14, and accordingly the particle 10 with an (electrically insulating) thin oxide layer 14 in all those peripheral areas, which are not connecting sections with a respective adjacent particle.
  • a typical resulting coating thickness on the particles after the gas treatment step S4 is about 10 nanometers. For example, by changing the pressure or temperature or exposure time, this layer thickness can be influenced.
  • a subsequent second compacting step S5 is typically performed as pressing at high temperature, in particular by means of hot hydrostatic pressure. see pressing done; typical process parameters are a pressing pressure of up to approx. 4000 bar at 1200 ° C temperature.
  • These very shallow oxide layer sections thus have typical lengths in the range of about 10 dis 150% of the original particle size of the particles and are very thin compared to this dimension, namely again in the nanometer range (usually 5 to about 30 nanometers).
  • these oxide layer sections act as eddy current barriers in the micro range according to the invention, while at the same time permitting final compression in a subsequent step S6 by rolling in a subsequent step S6 into an intended final shape and in the subsequent step S7 a machining aftertreatment experiences) very favorable magnetic properties with regard to high saturation flux density and low coercive field strength, whereby even at the scale of a known free-cutting steel (eg 1.0715), which is frequently used for DC applications, favorable behavior is realized.
  • a fabric is also significantly superior to a typical reference material for AC applications (such as FeSi3).

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Powder Metallurgy (AREA)
  • Soft Magnetic Materials (AREA)

Abstract

The invention relates to a method for producing a magnetizable metal shaped body comprising a ferromagnetic starting material that is present in powder and in particulate form, using the following steps: - first compaction of the starting material (S3) such that adjoining particles become bonded to each other by means of positive adhesion and/or integral bonding in sections along the peripheral surfaces thereof and while forming hollow spaces, - creating an electrically isolating surface coating on the peripheral surfaces of the particles in regions outside the joining sections (S4) and - second compaction of the particles (S5) provided with said surface coating, such that the hollow spaces are reduced in size or eliminated.

Description

Verfahren zum Herstellen eines magnetisiβrbaren metallischen Formkörpers Process for producing a magnetizable metallic shaped body
Die vorliegende Erfindung betrifft ein Verfahren zum Herstellen eines magnetisierbaren metallischen Formkörpers, einen durch ein solches Verfahren hergestellten Formkörper sowie Verwendungen eines derartigen Formkörpers.The present invention relates to a method for producing a magnetizable metallic shaped article, a molded article produced by such a method and uses of such a shaped article.
Aus dem Stand der Technik sind zahlreiche magnetisierbare metallische Körper zum Realisieren verschiedenster elektromagnetischer Vorrichtungen, etwa elektromagnetischer Aktoren, Transformatoren oder dergleichen, bekannt. All diesen Anwendungen ist gemeinsam, dass ein zur Herstellung der magnetisierbaren Bestandteile und Baugruppen verwendetes Material einerseits günstige magnetische Eigenschaften in Form einer möglichst hohen (Sättigungs-) Flussdichte bei kleiner Erregung und geringer Koerzitivfeidstärke aufweisen soll, wobei Reineisen (bzw. Werkstoffe aus Eisen bzw. aus Eisen-Silizium-Legierungen) im Hinblick auf derartige magnetische Eigenschaften besonders günstig ist.Numerous magnetizable metallic bodies are known in the prior art for realizing various electromagnetic devices, such as electromagnetic actuators, transformers or the like. All these applications have in common that a material used for the production of the magnetizable components and assemblies on the one hand should have favorable magnetic properties in the form of the highest possible (saturation) flux density at low excitation and low coercive field strength, with pure iron (or materials made of iron or made of iron-silicon alloys) in view of such magnetic properties is particularly favorable.
Andererseits entstehen insbesondere bei mit Wechselströmen angesteuerten Magneten (hier werden die Werkstoffe im Takt der Wechselstromfrequenz ummagnetisiert ) Verluste insbesondere in Form von Wirbelstromverlusten; diese sind das Ergebnis von durch das magnetische Wechselfeld induzierten Spannungen, die Wirbelströme senkrecht zum magnetischen Wechselfeld bewirken und das magnetische Feld schwächen (mithin einen Energieverlust bewirken) . Zur Verminderung derartiger Wirbelstromverluste ist es wiederum bekannt, das magnetisierbare Material widerstandserhöhend zu beeinflussen, etwa in Form von Blechen bei Transformatoren oder durch das Bilden von Mischkristallen (z. B. FeNi) im magnetischen Werkstoff. Eine derartige Erhöhung des (spezifischen) elektrischen Widerstands reduziert die beschriebenen Wirbelstromverluste, setzt jedoch gleichzeitig die magneti- sehe Sättigungsflussdichte herab und beeinträchtigt zudem mechanische Eigenschaften, etwa die Festigkeit.On the other hand, in particular in the case of magnets controlled by alternating currents (here the materials are reversed in the cycle of the alternating current frequency) losses occur, in particular in the form of eddy current losses; These are the result of induced by the magnetic alternating field voltages that cause eddy currents perpendicular to the alternating magnetic field and weaken the magnetic field (thus cause an energy loss). To reduce such eddy current losses, it is again known to increase the magnetizable material to increase resistance, for example in the form of sheets in transformers or by forming mixed crystals (eg FeNi) in the magnetic material. Such an increase in the (specific) electrical resistance reduces the described eddy current losses, but at the same time reduces the magnetic saturation flux density and also impairs mechanical properties, such as strength.
Auch bei Gleichstromanwendungen sind jedoch die negativen Auswirkungen von Wirbelströmen nicht gänzlich unbeachtlich; so führt etwa das mit einem Schaltvorgang verbundene Auf- magnetisieren zu Wirbelströmen, welche magnetisch entgegenwirken und die Dynamik bzw. erreichbare Bewegungsgeschwindigkeit von Aktoren oder dergleichen mit Gleichstrom betriebenen Magnetanwendungen begrenzen.Even with DC applications, however, the negative effects of eddy currents are not completely irrelevant; Thus, for example, the magnetization associated with a switching operation leads to eddy currents which counteract magnetically and limit the dynamics or achievable speed of movement of actuators or the like with DC-operated magnet applications.
Wirbelstromverluste sind zudem stark frequenzabhängig, so- dass insbesondere bei Hochfrequenzanwendungen es auch etwa bekannt ist, zur Erhöhung des spezifischen elektrischen Widerstands Pulververbundwerkstoffe aus einem Metallpulver einzusetzen, welches mit einem z. B. polymeren Bindemittel verpresst wird. Neben dem relativ hohen elektrischen Widerstand relativ etwa zu einem Blech besitzt eine derartige Vorgehensweise zudem den Vorteil, dass Wirbelströme dreidimensional unterdrückt werden können. Allerdings sind die magnetischen Eigenschaften derartiger Pulververbundwerkstoffe häufig ungenügend, so liegt etwa eine typische Sättigungsflussdichte eines Metalls um das 1,5 bis etwa 5- fache höher als bei derartigen in Kunststoff gebundenen Metallpulvern. Auch hier weist ein so hergestellter Formkör- per mangelhafte mechanische Eigenschaften, etwa in Form der mechanischen Festigkeit, auf. Aus dem bekannten Stand der Technik ist es daher eine bekannte Herausforderung, durch geeignete Auswahl und Ausbildung des metallisierbaren Materials die beschriebenen, zueinander potenziell gegensätzlichen Eigenschaften im Hin- blick auf die jeweilige Anwendung zu optimieren, nämlich möglichst günstige magnetische Eigenschaften mit möglichst geringen Wirbelstromverlusten, bei notwendigen mechanischen Eigenschaften, etwa akzeptabler Festigkeit, in Einklang zu bringen.Eddy current losses are also highly frequency-dependent, so that it is also known, for example in high-frequency applications, to increase the specific electrical resistance use powder composite materials of a metal powder, which with a z. B. polymeric binder is pressed. In addition to the relatively high electrical resistance relative to a sheet such a procedure also has the advantage that eddy currents can be suppressed three-dimensional. However, the magnetic properties of such powder composites are often insufficient, such as a typical saturation flux density of a metal is 1.5 to about 5 times higher than such plastic bound metal powders. Here too, a molded article produced in this way has inadequate mechanical properties, for example in the form of mechanical strength. From the known state of the art, it is therefore a known challenge to optimize the described, mutually potentially conflicting properties with regard to the respective application by suitable selection and formation of the metallizable material, namely the most favorable magnetic properties with the lowest possible eddy current losses necessary mechanical properties, such as acceptable strength, to reconcile.
Aufgabe der vorliegenden Erfindung ist es daher, einen mag- netisierbaren metallischen Formkörper sowie ein Verfahren zum Herstellen eines solchen zu schaffen, womit einerseits energetisch nachteilige Wirbelströme wirksam unterdrückt bzw. minimiert werden können, andererseits nach wie vor günstige magnetische Eigenschaften, insbesondere hohe magnetische (Sättigungs-) Flussdichte und niedrige Koerzitiv- feldstärke, gewährleistet werden können, wobei ein solcher Formkörper auch verbesserte mechanische Eigenschaften (etwa gegenüber bekannten Pulver- bzw. Sinterwerkstoffen) aufweisen soll. Ferner sind geeignete Verwendungen für ein derartiges Verfahren bzw. dadurch realisierte Formkörper zu schaffen .The object of the present invention is therefore to provide a magnetizable metallic molded body and a method for producing such, on the one hand energetic adverse eddy currents can be effectively suppressed or minimized, on the other hand still favorable magnetic properties, especially high magnetic (saturation -) flux density and low coercive field strength, can be ensured, wherein such a shaped body should also have improved mechanical properties (as compared to known powder or sintered materials). Furthermore, suitable uses for such a method or molded bodies realized thereby are to be created.
Die Aufgabe wird durch das Verfahren mit den Merkmalen des Hauptanspruchs, den durch das Verfahren hergestellten Formkörper sowie Verwendungen des Formkörpers gelöst; vorteilhafte Weiterbildungen der Erfindung sind in den Unteransprüchen beschrieben.The object is achieved by the method having the features of the main claim, the molded body produced by the method and uses of the molding; advantageous developments of the invention are described in the subclaims.
Der Erfindung liegt zunächst die Erkenntnis zugrunde, dass dann, wenn Wirbelströme bereits im Mikrobereich (d. h. im Bereich der Korn- bzw. Partikelgröße des pulverförmigen ferromagnetischen Ausgangsmaterials) begrenzt werden, günstige magnetische Eigenschaften des resultierenden Formkörpers erreicht werden. Dementsprechend ermöglicht es das erfindungsgemäße Verfahren, durch ein Vorverdichten in Form des Schrittes des erstes Verdichtens des Ausgangsmaterials bereits einen (mechanisch stabilen) Körper durch den Formbzw. Stoffschluss (etwa in Form von Brücken) zwischen den benachbarten Partikeln zu schaffen, wobei im nachfolgenden Schritt des Erzeugens der elektrisch isolierenden Oberflä- chenbeschichtung auf den Partikeln erfindungsgemäß die Hohlräume (weiterbildungsgemäß durch das Einleiten eines entsprechend reaktiven Gases) genutzt werden, um diejenigen Oberflächenabschnitte der Partikel, die außerhalb der Verbindungsabschnitte (Brücken) zu einem jeweils benachbarten Partikel liegen, mit einer (relativ zur Partikelgröße) sehr dünnen partiellen Beschichtung zu versehen. Das anschließende zweite Verdichten führt dann dazu, dass die Hohlräume beseitigt oder stark verkleinert werden, sodass im Ergebnis eine stark komprimierte Partikelstruktur mit Schichtab- schnitten der isolierten (Oberflächen-) Beschichtung vorliegt, die -- in Mikrogröße und im Körper verteilt -- den erfindungsgemäß beabsichtigten Effekt der Wirbelstrombarrieren im Mikrobereich bewirken. Mit anderen Worten, die Erfindung ermöglicht das Erzeugen eines magnetisierbaren metallischen Werkstoffs als Formkörper, in welchen (dreidimensional) elektrisch nicht leitende, dünne (in der Schichtdicke üblicherweise lediglich im Nanometerbereich liegende) Schichtabschnitte verteilt vorliegen, welche als wirksame Wirbelstrombarrieren dienen.The invention is based first of all on the knowledge that when eddy currents are already in the micro range (ie in the range of the particle size or particle size of the pulverulent particle) ferromagnetic starting material) are limited, favorable magnetic properties of the resulting molded body can be achieved. Accordingly, the method according to the invention, by pre-compression in the form of the step of first compressing the starting material already allows a (mechanically stable) body by the Formbzw. In the subsequent step of producing the electrically insulating surface coating on the particles, the cavities (in accordance with the further development by the introduction of a correspondingly reactive gas) are used to form those surface sections of the particles Particles that are located outside of the connecting sections (bridges) to a respective adjacent particle, to be provided with a very thin (relative to the particle size) partial coating. The subsequent second compaction then leads to the cavities being eliminated or greatly reduced so that, as a result, there is a highly compressed particle structure with layer sections of the isolated (surface) coating which, distributed in micro size and in the body, according to the invention effect intended effect of the eddy current barriers in the micro range. In other words, the invention makes it possible to produce a magnetizable metallic material as a shaped body, in which (three-dimensionally) electrically non-conductive, thin layer layers (usually only in the nanometer range in the layer thickness) are distributed, which serve as effective eddy current barriers.
Der so erzeugte Formkörper besitzt dann nicht nur die erwünschte hohe magnetische Leistungsdichte (welche potenziell an Reineisenmaterial heranreicht) , auch werden die Wirbelstromverluste durch Wirkung der dreidimensional im Korper verteilten Schichtabschnitte signifikant reduziert. Damit entsteht dann etwa die Möglichkeit, mit verbessertem energetischen Wirkungsgrad (ressourcenschonend) elektromag- netische Einheiten, z. B. Aktoren, zu gestalten, wobei die realisierte hohe Flussdichte bei kleiner Erregung kompakte Vorrichtungen ermöglicht, die entsprechend Bauraum einsparen und andere Vorteile bringen.The shaped body thus produced not only has the desired high magnetic power density (which potentially comes close to pure iron material), also the Eddy current losses significantly reduced by the effect of the three-dimensionally distributed in the body layer sections. This then gives rise to the possibility, for example, of improving the energy efficiency (resource-saving) of electromagnetic units, eg. As actuators to make, with the high flux density realized at low excitation compact devices that save space and bring other benefits.
Ein weiterer Vorteil der Erfindung liegt zudem darin, dass ein erfindungsgemaß realisierter Formkorper herausragende mechanische Eigenschaften aufweist, insbesondere im Hinblick auf Stabilität, Zug- und Bruchfestigkeit, vor allem gegenüber traditionell bekannten Werkstoffen und Werkstoff- anordnungen zur Minimierung von Wirbelstromverlusten. So scheint es etwa ohne weiteres realisierbar, dass gemäß der vorliegenden Erfindung elektromagnetische Eigenschaften eines erfindungsgemaß realisierten Formkorpers erreicht werden, welche die einem typischen Referenzmaterial wie etwa FeSi3 entsprechen, jedoch in mechanischer Hinsicht diesem Material gegenüber signifikant verbesserte Eigenschaften aufweisen. Dies erscheint etwa vor dem Hintergrund plausibel, dass m vorteilhafter Realisierung der Erfindung die erfindungsgemaße Erzeugung der isolierenden Oberflachenbe- Schichtung erfolgt, nachdem im ersten Schritt des Verdich- tens des Ausgangsmaterials zueinander benachbarte Partikel über Bruckenbildung od.dgl. miteinander verbunden wurden und dementsprechend eine gunstige Grundfestigkeit des Korpers bewirken.A further advantage of the invention resides in the fact that a shaped body realized according to the invention has outstanding mechanical properties, in particular with regard to stability, tensile strength and breaking strength, in particular over traditionally known materials and material arrangements for minimizing eddy current losses. For example, it may be readily realized that, in accordance with the present invention, electromagnetic properties of a molded article made in accordance with the present invention can be achieved that correspond to a typical reference material such as FeSi3, but have significantly improved mechanical properties with respect to this material. This seems plausible against the background that m advantageous realization of the invention, the inventive generation of the insulating Oberflachenbe- layering takes place after in the first step of compaction of the starting material adjacent particles to each other via bridging or the like. have been joined together and accordingly cause a favorable basic strength of the body.
In erfindungsgemaß gunstiger Weise ist in der praktischen Durchfuhrung das reaktive Gas, welches in die Hohlräume (in der Art eines zusammenhangenden Porenraums) nach dem ersten Verdichtungsschritt eingebracht wird, ein ein Oxidieren oder Nitrieren der Partikeloberflachen außerhalb der Verbindungsabschnitte (Brücken) bewirkendes Gas, wobei ein solches Gas auch ein kohlenstoff-, Stickstoff-, sauerstoff- , schwefel- und/oder bor-haltiges Gas sein kann. Auch liegt es im Rahmen der Erfindung, ein solches Gas nicht gesondert zuzuführen, sondern als reaktives Gas dasjenige zu benutzen, welches (residual) bereits im pulverformigen Ausgangsmaterial vorliegt und/oder wahrend des ersten Verdichtungs- Vorgangs entsteht bzw. gebildet wird, wobei in diesem Fall der Schritt des Erzeugens der elektrisch isolierenden Ober- flachenbeschichtung mit dem ersten Verdichten erfolgt.In accordance with the invention favorable manner in the practical implementation of the reactive gas, which in the cavities (in the manner of a coherent pore space) after the first Compressing step is introduced, a oxidizing or nitriding of the particle surfaces outside of the connecting portions (bridges) causing gas, wherein such gas may also be a carbon, nitrogen, oxygen, sulfur and / or boron-containing gas. It is also within the scope of the invention to supply such a gas not separately, but to use as reactive gas that (residual) is already present in the powdery starting material and / or formed or formed during the first compression process, wherein in this Case, the step of generating the electrically insulating top flat coating with the first compression takes place.
Wahrend zudem im Rahmen bevorzugter Ausfuhrungsformen der Erfindung beim Schritt des ersten Verdichtens ein (bevorzugt isostatisches und/oder kaltes hydrostatisches) Pressen mit dem ersten Pressdruck von mehr als 300 bar, typischerweise von 1000 bar oder mehr, erfolgt, ist das zweite Verdichten nach dem Erzeugen der isolierenden Oberflachenbe- Schichtung ein typischerweise durch heißes hydrostatisches Pressen mit einem signifikant höheren Pressdruck von bis zu ca. 4000 bar durchgeführter Prozess. Dieser Pressdruck bei einer typischen Temperatur oberhalb 10000C fuhrt zu einem Fließen des Materials, mit dem Ergebnis, dass sich (bei ei- nem signifikanten Reduzieren der Poren bzw. gar deren Verschwinden) die Schichtabschnitte der isolierenden Oberfla- chenbeschichtung (die jeweils, bei einer Dicke im typischen Nanometerbereich eine Langenerstreckung entsprechend ungefähr der Ausgangsmaterial-Korngroßen besitzen) im resultie- renden Formkorper verteilt vorliegen und die beabsichtigte wirbelstromhemmende Wirkung auf Mikroebene ermöglichen. Weiterbildungsgemäß ist es von der Erfindung umfasst, den metallischen Formkörper nach dem zweiten Verdichten einem mechanischen Umformschritt und/oder einer spanenden Nachbehandlung zu unterziehen, um in soweit den Formkörper für den beabsichtigten Einsatzzweck auszuformen. Geeignet kann zudem ein Umformschritt wie Walzen, Ziehen oder dergleichen dafür sorgen, dass eine Isotropie der im Formkörper verteilten Schichtabschnitte gezielt verändert werden kann.While in the context of preferred embodiments of the invention in the step of first compacting a (preferably isostatic and / or cold hydrostatic) pressing with the first pressing pressure of more than 300 bar, typically 1000 bar or more, takes place, the second compression after the production the insulating surface layering a typically by hot hydrostatic pressing with a significantly higher pressure of up to about 4000 bar performed process. This compacting pressure at a typical temperature above 1000 0 C leads to a flow of the material, with the result that (in a significant reduction of the pores or even their disappearance) chenbeschichtung the portions of the insulating layer Oberfla- (each, wherein a thickness in the typical nanometer range have a long extension corresponding to approximately the starting material grain sizes) distributed in the resulting Formkorper and allow the intended vortex current-limiting effect at the micro level. According to the invention, it is encompassed by the invention to subject the metallic shaped body to a mechanical forming step and / or a subsequent treatment after the second compacting in order to mold the shaped body for the intended purpose. In addition, a forming step such as rolling, drawing or the like can suitably ensure that an isotropy of the layer sections distributed in the shaped body can be specifically changed.
Während es einerseits von der Erfindung umfasst ist, als ferromagnetisches Ausgangsmaterial unbeschichtete ferromag- netische Partikel, etwa Reineisenpartikel, zu verwenden, sieht eine alternative Ausführungsform der Erfindung vor, dass dem erfinderischen Prozess in Pulverform vorliegende Partikel zugeführt werden, welche selbst als beschichtete Partikel, z. B. Eisenpartikel, mit (anderer) Metallbe- schichtung oder Halbleiterbeschichtung, vorliegen (z. B. durch vorgelagerte Plasmabeschichtung) . Damit lässt sich dann einerseits das mechanische Verbindungsverhalten (z. B. die Qualität der Sinterbrücken) nach dem Schritt des ersten Verdichtens beeinflussen, andererseits ermöglicht eine derartige Vorbeschichtung der Partikel, durch gezielte Ausbildung des in den Porenraum einzubringenden reaktiven Gases günstige isolierende Oberflächen herzustellen (z. B. eine Aluminiumoxid-Oberflächenbeschichtung durch Oxidation eines mit Aluminium vorbeschichteten Eisenpartikels mit Hilfe des Beschichtungsschrittes) .While it is on the one hand encompassed by the invention to use uncoated ferromagnetic particles, such as pure iron particles, as the ferromagnetic starting material, an alternative embodiment of the invention provides for the inventive process to be supplied with powdered particles which themselves act as coated particles, e.g. , Example, iron particles, with (other) metal coating or semiconductor coating, are present (eg by upstream plasma coating). On the one hand, this makes it possible on the one hand to influence the mechanical connection behavior (for example the quality of the sintered bridges) after the step of the first compacting, on the other hand enables such precoating of the particles to produce favorable insulating surfaces by targeted formation of the reactive gas to be introduced into the pore space (eg B. an aluminum oxide surface coating by oxidation of an aluminum precoated iron particle by means of the coating step).
Der auf die beschriebene Weise erfindungsgemäß erzeugte Formkörper ist prinzipiell einer großen Anzahl von magneti¬ schen Anwendungen zugänglich, wobei die vorbeschriebenen Vorteile im Hinblick auf Wirkungsgrad, magnetisches Verhal¬ ten, mechanische Kompaktheit und Stabilität jeweils geeig- net instrumentalisiert werden können - so erstreckt sich die potenzielle Einsatzbreite der vorliegenden Erfindung von magnetischen Aktoren oder Antriebsvorrichtungen (wie etwa elektromagnetischen Stellgliedern und Elektromotoren) über den Einsatz in Transformatoren und anderen Gebieten der Leistungselektronik bis hin zu elektromagnetischen Lagern und Aufgaben der Hochfrequenztechnik. The shaped body in the manner described according to the invention is produced in principle accessible to a large number of magneti ¬ rule applications, wherein the advantages described above with regard to efficiency, magnetic Verhal ¬ th, mechanical compactness and stability of each SITUATE can be instrumentalized - so extends the potential range of application of the present invention of magnetic actuators or drive devices (such as electromagnetic actuators and electric motors) on the use in transformers and other areas of power electronics to electromagnetic bearings and tasks of high-frequency technology.
Weitere Vorteile, Merkmale und Einzelheiten der Erfindung ergeben sich aus der nachfolgenden Beschreibung bevorzugter Ausfuhrungsbeispiele sowie anhand der Zeichnungen; diese zeigen inFurther advantages, features and details of the invention will become apparent from the following description of preferred exemplary embodiments and with reference to the drawings; these show in
Figur 1: Ein Flussablaufdiagramm mit Prozessschritten Sl bis S7 zum Durchfuhren des erfindungsgemaßen Verfahrens gemäß einer ersten Ausfuhrungsform undFigure 1: A flow chart with process steps Sl to S7 for carrying out the inventive method according to a first embodiment and
Figur 2: Eine Ansicht mit einer Mehrzahl von schematischen Illustrationen, welche entlang der Schritte Sl bis S6 von Figur 1 die prozessgemaß veränderte Formgebung des Formkorpers bzw. der Partikel des Ausgangsmaterials illustrieren.FIG. 2: a view with a plurality of schematic illustrations, which illustrate the process-related changed shaping of the shaped body or of the particles of the starting material along the steps S 1 to S 6 of FIG. 1.
Gemäß einem ersten Prozessschritt wird pulverformiges Eisen-Rohmaterial einer typischen durchschnittlichen Korngroße im Bereich von ca. lOμm bis 500μm bereitgestellt; die Bezugszeichen 10 verdeutlichen zum Prozessschritt Sl das Vorliegen derartiger Pulverpartikel im unbeschichteten Zustand. Typische, handelsübliche Pulvermaterialien im Hinblick auf eine vergleichsweise kleine Korngroße sind z.B. Reineisenpulver (Fe2) mit Korngroße < 30μm, D50 (mittlere Korngroße) 9μm bis llμm des Herstellers ThyssenKrupp Metal- lurgie, im Fall einer größeren Korngroße sei exemplarisch auf das Produkt Ampersint (verduste Fe-Basis Pulver der Firma HC Starck GmbH) verwiesen, hier betragt die Korngroße Fe zu mindestens 99,5 (Gew-)% kleiner 350 μm. Alternative Fe-Basispulver dieses Herstellers sind FeSi3 oder FeSiβ mit entsprechender Korngroße.According to a first process step, powdered iron raw material of a typical average grain size in the range of about 10 μm to 500 μm is provided; the reference numeral 10 illustrate the process step Sl, the presence of such powder particles in the uncoated state. Typical commercial powder materials in view of a comparatively small grain size are e.g. Pure iron powder (Fe2) with grain size <30μm, D50 (average grain size) 9μm to llμm of the manufacturer ThyssenKrupp Metallurgie, in the case of a larger grain size is exemplified in the product Ampersint (verduste Fe-base powder from HC Starck GmbH), here the grain size Fe amounts to at least 99.5 (wt)% less than 350 μm. Alternative Fe base powders of this manufacturer are FeSi3 or FeSiβ with corresponding grain size.
Prozessschritt S2 als fakultativer Prozessschritt sieht die Möglichkeit vor, dass vor einem nachfolgenden ersten Ver- dichten (Schritt S3) die Pulverpartikel des Rohmaterials, etwa mittels Plasmabeschichten oder dergleichen mit einer Metallisierung oder Halbleiterbeschichtung versehen werden. Diese im Schritt S2 fakultativ aufzubringende Schicht ist dünn gegenüber dem betreffenden Partikeldurchmesser und liegt typischerweise im Bereich zwischen 5 und 50nm.Process step S2 as an optional process step provides the possibility that before a subsequent first dense (step S3) the powder particles of the raw material, for example by means of plasma coatings or the like are provided with a metallization or semiconductor coating. This optional layer to be applied in step S2 is thin relative to the respective particle diameter and is typically in the range between 5 and 50 nm.
Im nachfolgenden Prozessschritt S3 findet ein erstes Vorverdichten des (beschichteten oder unbeschichteten) Rohma- terials statt, typisch ist ein kaltes hydrostatisches Pressen mit einem Pressdruck von ca. 1000 bar. Es entsteht das in der Figur 2 (bei unbeschichtetem Rohmaterial) illustrierte Bild eines vorverdichteten Körpers, bei welchem mittels Sinterbrücken die Partikel 10 mechanisch fest aneinan- der haften.In the subsequent process step S3, a first precompression of the (coated or uncoated) raw material takes place, typically a cold hydrostatic pressing with a compression pressure of about 1000 bar. The result is the image of a precompressed body illustrated in FIG. 2 (in the case of uncoated raw material), in which the particles 10 are adhered to one another mechanically by means of sintered bridges.
Im nachfolgenden Prozessschritt S4 wird ein oxidierendes Gas, im vorliegenden Fall Sauerstoff, bei einem Druck von 0,01 bar und einer Temperatur von 3500C so in den Formkör- per eingebracht, dass dieses Gas in die Hohlräume 14 eintritt und entsprechend die Partikel 10 mit einer (elektrisch isolierenden) dünnen Oxidschicht 14 in all jenen Um- fangsbereichen versieht, die keine Verbindungsabschnitte mit einem jeweils benachbarten Partikel sind. Eine typische resultierende Beschichtungsdicke auf den Partikeln nach dem Gasbehandlungsschritt S4 (Dauer im beschriebenen Beispiel 30 min) liegt bei ca. 10 Nanometern. Beispielsweise durch Veränderung von Druck oder Temperatur oder Einwirkzeit lässt sich diese Schichtdicke beeinflussen.In subsequent process step S4 is an oxidizing gas, bar, in this case oxygen, at a pressure of 0.01 and a temperature of 350 0 C as inserted into the Formkör- by that this gas enters the cavities 14, and accordingly the particle 10 with an (electrically insulating) thin oxide layer 14 in all those peripheral areas, which are not connecting sections with a respective adjacent particle. A typical resulting coating thickness on the particles after the gas treatment step S4 (duration in the example described 30 minutes) is about 10 nanometers. For example, by changing the pressure or temperature or exposure time, this layer thickness can be influenced.
Ein nachfolgender zweiter Verdichtungsschritt S5 (sogenanntes Konsolidieren) wird typischerweise als Verpressen bei hoher Temperatur, insbesondere mittels heißen hydrostati- sehen Pressens durchgeführt; typische Prozessparameter sind ein Pressdruck von bis zu ca. 4000 bar bei 12000C Temperatur. Dies fuhrt dazu, dass — vergleiche die Illustration in Figur 2 zu S5 -- die Poren (Zwischenräume) 12 verschwin- den bzw. sich deutlich verkleinern, sodass im endverdichteten Material am Ende des Prozessschritts S5 im Wesentlichen nur noch Oxidschichtabschnitte 14 verteilt im Material verbleiben, welche den ursprunglichen Beschichtungsab- schnitten auf den Umfangsflachen der Partikel bzw. kompri- mierten Poren entsprechen. Diese sehr flachen Oxidschicht- Abschnitte weisen damit typische Langen im Bereich von ca. 10 Dis 150 % der ursprunglichen Korngroße der Partikel auf und sind gegenüber dieser Dimension sehr dünn, nämlich wiederum im Nanometer-Bereich (üblicherweise 5 bis ca. 30 Na- nometer) .A subsequent second compacting step S5 (so-called consolidation) is typically performed as pressing at high temperature, in particular by means of hot hydrostatic pressure. see pressing done; typical process parameters are a pressing pressure of up to approx. 4000 bar at 1200 ° C temperature. This leads to the fact - compare the illustration in Figure 2 to S5 - the pores (interstices) disappear or shrink significantly, so that in the end-compacted material at the end of the process step S5 substantially only oxide layer portions 14 remain distributed in the material which correspond to the original coating sections on the peripheral surfaces of the particles or compressed pores. These very shallow oxide layer sections thus have typical lengths in the range of about 10 dis 150% of the original particle size of the particles and are very thin compared to this dimension, namely again in the nanometer range (usually 5 to about 30 nanometers). ,
Durch ihre Verteilung im endverdichteten Material wirken diese Oxidschichtabschnitte als erfindungsgemaß wirksame Wirbelstromhemmnisse im Mikrobereich, gleichzeitig ermog- licht das so realisierte endverdichtete Material (welches im gezeigten Ausfuhrungsbeispiel in einem nachfolgenden Schritt S6 durch Walzen noch eine Umformung in eine beabsichtigte Endform sowie im nachfolgenden Schritt S7 noch eine spanende Nachbehandlung erfahrt) sehr gunstige magne- tische Eigenschaften im Hinblick auf hohe Sattigungsfluss- dichte und niedrige Koerzitivfeidstarke, wobei selbst am Maßstab eines bekannten Automatenstahls (z. B. 1.0715), welcher häufig für Gleichstromanwendungen herangezogen wird, gunstiges Verhalten realisiert wird. Ein so herge- stelltes Material ist ferner einem typischen Referenzmaterial für Wechselstromanwendungen (etwa FeSi3) deutlich überlegen . As a result of their distribution in the final compacted material, these oxide layer sections act as eddy current barriers in the micro range according to the invention, while at the same time permitting final compression in a subsequent step S6 by rolling in a subsequent step S6 into an intended final shape and in the subsequent step S7 a machining aftertreatment experiences) very favorable magnetic properties with regard to high saturation flux density and low coercive field strength, whereby even at the scale of a known free-cutting steel (eg 1.0715), which is frequently used for DC applications, favorable behavior is realized. Such a fabric is also significantly superior to a typical reference material for AC applications (such as FeSi3).

Claims

Patentansprüche claims
1. Verfahren zum Herstellen eines magnetisierbaren metal- lischen Formkörpers aus einem pulverförmig und in Partikelform vorliegenden ferromagnetischen Ausgangsmaterial (10), mit den Schritten:1. A process for producing a magnetizable metallic shaped body from a powdery and particulate ferromagnetic starting material (10), comprising the steps of:
- erstes Verdichten des Ausgangsmaterials (S3), sodass benachbarte Partikel durch Form- und/oder Stoff- Schluss abschnittsweise an ihrer Umfangsflache und unter Ausbildung von Hohlräumen (12) miteinander verbunden werden,first compacting of the starting material (S3) so that adjacent particles are connected to one another in sections at their peripheral surface by forming and / or material closing and by forming cavities (12),
Erzeugen einer elektrisch isolierenden Oberflächen- beschichtung (14) auf den Umfangsflachen der Parti- kel in Bereichen außerhalb der Verbindungsabschnitte (S4) undProducing an electrically insulating surface coating (14) on the peripheral surfaces of the particles in regions outside the connecting sections (S4) and
- zweites Verdichten der mit der Oberflächenbeschich- tung versehenen Partikel (S5) , sodass die Hohlräume verkleinert oder beseitigt werden.second compacting the surface-coated particles (S5) so that the voids are reduced or eliminated.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass das Erzeugen der elektrisch isolierenden Oberflächenbe- schichtung (S4) durch Einbringen eines durch Reaktion mit den Umfangflächen die Oberflächenbeschichtung er- zeugenden Gases in die Hohlräume erfolgt.2. Method according to claim 1, characterized in that the production of the electrically insulating surface coating (S4) takes place by introducing a gas which generates the surface coating by reaction with the circumferential surfaces into the cavities.
3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass das Erzeugen der elektrisch isolierenden Oberflächenbeschichtung durch ein Gas erfolgt, welches beim Schritt des ersten Verdichtens des Ausgangsmaterials bereits im oder mit dem Ausgangsmaterial vorhanden ist oder beim ersten Verdichten entsteht. 3. The method according to claim 1 or 2, characterized in that the generating of the electrically insulating surface coating is carried out by a gas which is already present in the step of the first compression of the starting material in or with the starting material or is formed during the first compression.
4. Verfahren nach Anspruch 2 oder 3, dadurch gekennzeichnet, dass das Gas ein kohlenstoff-, Stickstoff-, sauer- stoff-, schwefel- und/oder bor-haltiges Gas ist und/oder eine chemische Reaktion so bewirkt, dass die Umfangsflache außerhalb der Verbindungsabschnitte die elektrisch isolierende Oberflächenbeschichtung erfährt.4. The method according to claim 2 or 3, characterized in that the gas is a carbon, nitrogen, oxygen, sulfur and / or boron-containing gas and / or causes a chemical reaction so that the peripheral surface outside the connecting portions undergoes the electrically insulating surface coating.
5. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass die elektrisch isolierende Oberflä- chenbeschichtung eine Schichtdicke im Bereich zwischen 2nm und 50nm aufweist.5. The method according to any one of claims 1 to 4, characterized in that the electrically insulating surface chenfläichtung has a layer thickness in the range between 2nm and 50nm.
6. Verfahren nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass das erste Verdichten (S3) das Pres- sen des Ausgangsmaterials mit einem ersten Pressdruck von mehr als 50 bar, bevorzugt von mehr als 300 bar, weiter bevorzugt von mehr als 1.000 bar, aufweist.6. The method according to any one of claims 1 to 5, characterized in that the first compression (S3) the pressing of the starting material with a first pressing pressure of more than 50 bar, preferably more than 300 bar, more preferably more than 1,000 bar.
7. Verfahren nach Anspruch 6, dadurch gekennzeichnet, dass das erste Verdichten durch kaltes hydrostatisches oder isostatisches Pressen erfolgt.7. The method according to claim 6, characterized in that the first compaction is carried out by cold hydrostatic or isostatic pressing.
8. Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass das erste Verdichten durch Sintern und/oder Vorsintern eines durch Rütteln verdichteten Pulvers als ferromagnetischem Ausgangsmaterial erfolgt.8. The method according to any one of claims 1 to 7, characterized in that the first compaction is carried out by sintering and / or presintering of a compacted by shaking powder as a ferromagnetic starting material.
9. Verfahren nach Anspruch 8, dadurch gekennzeichnet, dass das Sintern oder Vorsintern durch thermische Behandlung und ohne ein Pressen erfolgt.9. The method according to claim 8, characterized in that the sintering or pre-sintering takes place by thermal treatment and without pressing.
10. Verfahren nach einem der Ansprüche 1 bis 9, dadurch gekennzeichnet, dass das zweite Verdichten (S5) ein Pres- sen der durch das erste Verdichten verdichteten und mit der elektrisch isolierenden Oberflachenbeschichtung versehenen Partikel mit einem zweiten Pressdruck aufweist, der hoher als der erste Pressdruck ist, insbe- sondere um mindestens 10 % hoher, bevorzugt um mindestens 200 % hoher.10. The method according to any one of claims 1 to 9, characterized in that the second compression (S5) a Pres- sen of compressed by the first compaction and provided with the electrically insulating surface coating particles having a second pressing pressure which is higher than the first compacting pressure, in particular by at least 10% higher, preferably at least 200% higher.
11. Verfahren nach einem der Ansprüche 6, 8 bis 10, dadurch gekennzeichnet, dass das erste und/oder zweite Verdich- ten durch heißes hydrostatisches oder isostatisches Pressen erfolgt.11. The method according to any one of claims 6, 8 to 10, characterized in that the first and / or second compaction takes place by hot hydrostatic or isostatic pressing.
12. Verfahren nach Anspruch 11, dadurch gekennzeichnet, dass das heiße hydrostatische oder isostatische Pressen beim zweiten Verdichten (S5)bei einer Temperatur und einem Pressdruck erfolgt, die ein Fließen der Partikel und/oder von Schichtabschnitten der isolierenden Ober- flachenbeschichtung bewirken.12. The method according to claim 11, characterized in that the hot hydrostatic or isostatic pressing in the second compression (S5) takes place at a temperature and a pressure which cause flow of the particles and / or layer portions of the insulating top flat coating.
13. Verfahren nach einem der Ansprüche 1 bis 12, gekennzeichnet durch den Schritt des Umformens (S6) , insbesondere Walzens oder Tiefziehens, des Formkorpers nach dem zweiten Verdichten.13. The method according to any one of claims 1 to 12, characterized by the step of forming (S6), in particular rolling or deep drawing, of the molded article after the second compression.
14. Verfahren nach Anspruch 13, dadurch gekennzeichnet, dass das Umformen ein Verandern und/oder Beseitigen einer Isotropie von im Formkorper nach dem zweiten Verdichten vorliegenden Schichtabschnitten der isolierenden Oberflachenbeschichtung bewirkt.14. The method according to claim 13, characterized in that the forming causes a change and / or elimination of an isotropy of present in Formkorper after the second compaction layer portions of the insulating surface coating.
15. Verfahren nach einem der Ansprüche 1 bis 14, dadurch gekennzeichnet, dass das ferromagnetische Ausgangsmaterial unbeschichtete Eisenpartikel aufweist. 15. The method according to any one of claims 1 to 14, characterized in that the ferromagnetic starting material comprises uncoated iron particles.
16. Verfahren nach einem der Ansprüche 1 bis 15, dadurch gekennzeichnet, dass das ferromagnetische Ausgangsmaterial mit einem Metall- oder Halbleitermaterial be- schichtete Eisenpartikel aufweist.16. The method according to any one of claims 1 to 15, characterized in that the ferromagnetic starting material having coated with a metal or semiconductor material iron particles.
17. Verfahren nach Anspruch 16, dadurch gekennzeichnet, dass die Beschichtung der Eisenpartikel im Ausgangsmaterial eine Dicke von < 1000 nm, bevorzugt < 100 nm, weiter bevorzugt < lOnm, aufweist.17. The method according to claim 16, characterized in that the coating of the iron particles in the starting material has a thickness of <1000 nm, preferably <100 nm, more preferably <lOnm.
18. Verfahren nach einem der Ansprüche 15 bis 17, dadurch gekennzeichnet, dass eine mittlere Korngröße der als Pulver vorliegenden Partikel des ferromagnetischen Aus- gangsmaterials im Bereich zwischen 5 μm und 1000 μm liegt .18. The method according to any one of claims 15 to 17, characterized in that an average particle size of the powder present as particles of the ferromagnetic starting material in the range between 5 .mu.m and 1000 .mu.m.
19. Verfahren nach einem der Ansprüche 1 bis 18, dadurch gekennzeichnet, dass der metallische Formkörper zur Herstellung magnetisierbarer Bauteile von elektromagnetischen Aktor- und/oder Antriebsvorrichtungen, insbesondere eines elektromagnetischen Stellgliedes oder eines Elektromotors, einer magnetischen Lagerung oder eines Transformators verwendet wird.19. The method according to any one of claims 1 to 18, characterized in that the metallic shaped body for producing magnetizable components of electromagnetic actuator and / or drive devices, in particular an electromagnetic actuator or an electric motor, a magnetic bearing or a transformer is used.
20. Verfahren nach einem der Ansprüche 1 bis 18, dadurch gekennzeichnet, dass der Formkörper zur Herstellung eines Hochfrequenz-Bauelementes oder einer Hochfrequenz- Baugruppe verwendet wird. 20. The method according to any one of claims 1 to 18, characterized in that the shaped body is used for producing a high-frequency component or a high-frequency module.
EP09741823.0A 2008-05-09 2009-04-27 Method for producing a magnetizable metal shaped body Active EP2289082B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102008023059A DE102008023059B4 (en) 2008-05-09 2008-05-09 Method for producing a magnetizable metallic shaped body
PCT/EP2009/003041 WO2009135604A1 (en) 2008-05-09 2009-04-27 Method for producing a magnetizable metal shaped body

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EP2289082A1 true EP2289082A1 (en) 2011-03-02
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JP6872342B2 (en) * 2016-10-18 2021-05-19 株式会社ディスコ Cutting blade
KR102542094B1 (en) * 2018-05-30 2023-06-12 제이에프이 스틸 가부시키가이샤 Electrical steel sheet with insulation coating and method for manufacturing the same, iron core of transformer using the electrical steel sheet, transformer and method for reducing dielectric loss of transformer

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AT119411B (en) * 1928-02-11 1930-10-25 Siemens Ag Process for the production of bodies which are composed of grains or powder particles coated with an insulating layer.
DE1195882B (en) * 1955-06-08 1965-07-01 Siemens Ag Process for the production of a soft magnetic sintered body
JPS63199801A (en) * 1987-02-12 1988-08-18 Chisso Corp Stabilization treatment device for ferromagnetic metal powder
DE69028360T2 (en) * 1989-06-09 1997-01-23 Matsushita Electric Ind Co Ltd Composite material and process for its manufacture
US5993729A (en) * 1997-02-06 1999-11-30 National Research Council Of Canada Treatment of iron powder compacts, especially for magnetic applications
US6548012B2 (en) * 1999-05-28 2003-04-15 National Research Council Of Canada Manufacturing soft magnetic components using a ferrous powder and a lubricant
DE10066419B8 (en) * 1999-08-30 2015-09-17 Hitachi Metals, Ltd. A method of preserving (maintaining) an alloy powder material for an R-Fe-B type sintered magnet
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US8845957B2 (en) 2014-09-30
US20110058976A1 (en) 2011-03-10
CN102165540A (en) 2011-08-24
WO2009135604A1 (en) 2009-11-12
DE102008023059B4 (en) 2010-06-10

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