EP2877999B1 - Method of manufacturing an anisotropic magnet - Google Patents

Method of manufacturing an anisotropic magnet Download PDF

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EP2877999B1
EP2877999B1 EP13745634.9A EP13745634A EP2877999B1 EP 2877999 B1 EP2877999 B1 EP 2877999B1 EP 13745634 A EP13745634 A EP 13745634A EP 2877999 B1 EP2877999 B1 EP 2877999B1
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powder
extrusion
platelets
produced
anisotropic
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German (de)
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EP2877999A1 (en
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Gotthard Rieger
Martin Scharrer
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Siemens AG
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Siemens AG
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    • 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
    • B22F3/20—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by extruding
    • 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
    • H01F1/04—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 metals or alloys
    • H01F1/047—Alloys characterised by their composition
    • H01F1/053—Alloys characterised by their composition containing rare earth metals
    • H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
    • H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
    • H01F1/0571—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes
    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C2202/00—Physical properties
    • C22C2202/02—Magnetic
    • 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
    • H01F1/04—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 metals or alloys
    • H01F1/047—Alloys characterised by their composition
    • H01F1/053—Alloys characterised by their composition containing rare earth metals
    • H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
    • H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
    • H01F1/0571—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes
    • H01F1/0575—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together
    • H01F1/0576—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together pressed, e.g. hot working

Definitions

  • the invention relates to a method for producing an anisotropic magnet.
  • the permanent magnetic properties of magnetic materials are decisively determined by the structure or the microstructure.
  • micromagnetic theory and experimental findings it is known that in so-called nucleation-hardened magnets, high coercive field strengths can be achieved by a microstructural structure made up of single-domain, nanoscale grain structures. In principle, this makes it possible to dispense with the addition of more expensive additive elements.
  • this nanocrystalline microstructure is achieved by supercooling into the amorphous-nanocrystalline range.
  • the powder platelets produced in this way have nanocrystallites which do not yet have a uniform orientation in the form of a magnetocrystalline preferred direction. Orientation of the crystallite axes that is as rectified as possible is a prerequisite for achieving a correspondingly high remanescence. It is known to use common methods of sintering technology for producing anisotropic magnets, in which the powder particles are aligned in a magnetic field before the pressing and sintering process. However, the coercive field strength is limited by the microcrystalline grain size, which is usually in the range of a few micrometers, and must be compensated for by alloying expensive and relatively scarce rare earth metals, for example in the form of dysprosium.
  • the nanocrystalline powder is precompacted.
  • the precompacted nanocrystalline powder is formed in a second forming step.
  • the crystallite axes are aligned perpendicular to the surface of the plate by recrystallization.
  • An extension is the so-called backward extrusion, in which the material is typically formed from a solid cylinder into a hollow cylinder, the preferred direction of which leads to a desired diametrical preferred direction in accordance with the direction of flow and the shear forces that occur.
  • the US 2004/0025974 A1 discloses nanocrystalline and nanocomposite rare earth permanent magnet materials and methods of making magnets.
  • the magnetic materials can be isotropic or anisotropic and have no rare earth-rich phase.
  • the JP H06 224061 A discloses a manufacturing method for efficiently manufacturing an anisotropic rare earth magnet with high magnetic properties with a high yield.
  • the JP H03 14215 A discloses an extrusion melt process of a plastic mixed body containing magnetic powder and a binder.
  • " Extrusion of metal powders by continuous powder extrusion" ", Stephan Stadelmann, November 19, 2009, pages 1 to 145, XP055077332, dissertation, Technical Faculty of the University of Er Weg-Nuremberg discloses conventional powder extrusion using what is known as conforming technology. In the process, powder is fed into a gripping zone and a compression zone, this behavior being described in a deflection and prechamber area. Finally, the shows US 5,000 796 A.
  • anisotropic permanent magnets by extruding a rare earth magnet alloy below the melting temperature of the alloy at an extrusion ratio of 10: 1 to 26: 1. It is the object of the present invention to provide a method by means of which anisotropic magnets with a nanoscale grain structure can be produced while simultaneously orienting the crystallite axes as uniformly as possible.
  • the invention is based on the knowledge that continuous powder extrusion processes are particularly well suited for producing anisotropic magnets.
  • the powder platelets are continuously processed by typically heating them up to over 500 ° C. using a friction wheel and then pressing the resulting doughy material through a die arranged immediately after the friction wheel.
  • a completely different method for producing anisotropic magnets is used.
  • swirl areas also occur during the compression process, in which high orientation and shear of the flake-like powders can be expected. This leads to the alignment of the crystallite axes in the powder, which is necessary to build up anisotropic (textured) magnets. Compared to other methods, an additional area for shearing is therefore unnecessary.
  • the powder platelets are produced with a nanocrystalline grain size. This causes the powder platelets to have a high coercive field strength.
  • the powder platelets are produced by a melt-spinning process.
  • a material with special properties is produced by a very rapid cooling of a melt of the starting material from which the anisotropic magnet is made.
  • the cooling rates here are approximately 10,000 to 1,000,000 degrees per second. Due to the high rotational speed, the tape thus obtained is thrown off the wheel. Melt spinning allows powder platelets with a nanocrystalline microstructure to be obtained in a particularly simple manner by supercooling into the amorphous-nanocrystalline region.
  • a further advantageous embodiment of the invention provides that Nd 2 Fe 14 B is used as the starting material for the powder platelets.
  • Nd 2 Fe 14 B is used as the starting material for the powder platelets.
  • an alloy of neodymium, iron and boron is used, which has particularly good permanent magnetic properties.
  • An anisotropic magnet produced by the method according to the invention is produced by means of the method according to the invention.
  • the magnet has one nanoscale grain structure with essentially the same orientation of the crystallite axes.
  • the magnet has both a high coercive force and a high remanence.
  • a powder extrusion system 10 by means of which an anisotropic magnet 14 formed as an endless material is produced from magnetic powder platelets 12, is shown in a schematic sectional view in FIG Fig. 1 shown.
  • the powder platelets 12 are fed into a circumferential, unspecified groove of a rotating extrusion wheel 16.
  • the powder platelets 12 are transported by friction in the direction of movement, which is indicated by the arrow 18, of the extrusion wheel 16.
  • a part of the extrusion wheel 16 is covered by a stationary tool carrier 20 with a plurality of tool inserts, not shown here.
  • the extrusion wheel 16 and the tool carrier 20 thus form an extrusion chamber in which the added powder platelets 12 are heated by friction and shear.
  • the extrusion takes place radially through the die 22 to the extrusion wheel 16.
  • the powder platelets 12 are produced by means of a rapid solidification process.
  • the powder platelets 12 are produced by a melt-spinning process.
  • An alloy of neodymium, iron and boron with the composition Nd 2 Fe 14 B is used as the starting material for the magnetic powder platelets 12, which is first melted and placed on a copper wheel, which is usually cooled with water, where it immediately solidifies.
  • the tape obtained in this way is thrown off the wheel by a correspondingly high rotational speed of the copper wheel.
  • the magnetic powder flakes 12 are obtained by comminuting the tape obtained.
  • Fig. 2 the nanocrystalline grain size of the magnetic powder flakes 12 produced by means of the melt-spinning process is shown.
  • the powder platelets 12 usually have a length of a few hundred micrometers.
  • nanocrystallites 28 from which the magnetic powder platelets 12 are formed do not yet have a uniform orientation in the form of a magnetocrystalline preferred direction.
  • anisotropic magnets 14 with a high remanence and a high coercive force are produced in a particularly simple and inexpensive manner.
  • powder extrusion is characterized by a short process chain with a high degree of automation.
  • the shaping to the final geometry takes place in a single work step, whereby corresponding energy savings can be achieved by eliminating further shaping steps.
  • the use of lubricants can be dispensed with and there is also only a relatively short heat exposure time on the material, so that no undesired structural changes occur.

Description

Die Erfindung betrifft ein Verfahren zum Herstellen eines anisotropen Magneten. Die dauermagnetischen Eigenschaften von Magnetmaterialien werden neben der Legierungszusammensetzung entscheidend durch das Gefüge bzw. die Mikrostruktur bestimmt. Entsprechend der mikromagnetischen Theorie sowie experimenteller Befunde ist es bekannt, dass in sogenannten keimbildungsgehärteten Magneten durch einen mikrostrukturellen Aufbau aus eindomänigen, nanoskaligen Kornstrukturen hohe Koerzitivfeldstärken erzielt werden. Dies ermöglicht prinzipiell den Verzicht auf Zulegierung weiterer teurerer Additivelemente.
Bei Magneten, welche auf Basis der Rascherstarrungstechnik hergestellt werden, wird diese nanokristalline Mikrostruktur durch eine Unterkühlung in den amorph-nanokristallinen Bereich erzielt. Die dabei erzeugten Pulverplättchen weisen jedoch Nanokristallite auf, welche noch keine einheitliche Ausrichtung in Form einer magnetokristallinen Vorzugsrichtung aufweisen. Eine möglichst gleichgerichtete Orientierung der Kristallitachsen ist jedoch eine Voraussetzung dafür, eine entsprechend hohe Remaneszenz zu erzielen.
Es ist bekannt, gängige Verfahren der Sintertechnik zur Herstellung anisotroper Magnete einzusetzen, bei welchen die Pulverteilchen in einem Magnetfeld vor dem Press- und Sintervorgang ausgerichtet werden. Die Koerzitivfeldstärke ist jedoch durch die mikrokristalline Korngröße, welche üblicherweise im Bereich einiger Mikrometer ist, begrenzt und muss durch Zulegierung teurer und relativ knapper Seltenerdmetalle, beispielsweise in Form von Dysprosium, ausgeglichen werden.The invention relates to a method for producing an anisotropic magnet. In addition to the alloy composition, the permanent magnetic properties of magnetic materials are decisively determined by the structure or the microstructure. According to micromagnetic theory and experimental findings, it is known that in so-called nucleation-hardened magnets, high coercive field strengths can be achieved by a microstructural structure made up of single-domain, nanoscale grain structures. In principle, this makes it possible to dispense with the addition of more expensive additive elements.
In the case of magnets that are manufactured on the basis of rapid solidification technology, this nanocrystalline microstructure is achieved by supercooling into the amorphous-nanocrystalline range. However, the powder platelets produced in this way have nanocrystallites which do not yet have a uniform orientation in the form of a magnetocrystalline preferred direction. Orientation of the crystallite axes that is as rectified as possible is a prerequisite for achieving a correspondingly high remanescence.
It is known to use common methods of sintering technology for producing anisotropic magnets, in which the powder particles are aligned in a magnetic field before the pressing and sintering process. However, the coercive field strength is limited by the microcrystalline grain size, which is usually in the range of a few micrometers, and must be compensated for by alloying expensive and relatively scarce rare earth metals, for example in the form of dysprosium.

Des Weiteren ist es bekannt, bei Rascherstarrungsverfahren zur Ausrichtung der zunächst isotropen Verteilung der Richtungen der magnetokristallinen, sogenannten leichten Achse der Kristalle verschiedene zweistufige Heißumformverfahren einzusetzen. Hierbei wird in einem ersten Umformschritt das nanokristalline Pulver vorkompaktiert. In einem zweiten Umformschritt wird das vorkompaktierte nanokristalline Pulver umgeformt. Hierbei erfolgt durch Rekristallisation eine Ausrichtung der Kristallitachsen senkrecht zur Fläche des Plättchens.Furthermore, it is known to use various two-stage hot forming processes in rapid solidification processes for aligning the initially isotropic distribution of the directions of the magnetocrystalline, so-called easy axis of the crystals. In a first forming step, the nanocrystalline powder is precompacted. The precompacted nanocrystalline powder is formed in a second forming step. The crystallite axes are aligned perpendicular to the surface of the plate by recrystallization.

Beim Heißpressen (sogenannter Batch-Prozess) werden Scherzonen erzeugt, die zum einen eine Ausrichtung der Plättchen in Fließrichtung zur Folge hat, und zum anderen zu einer Verformung zu einer gewünschten Form der herzustellenden Magneten führt. Der erzielbare gleichgerichtete Orientierungsgrad der Nanokristallite ist in diesem Verfahren jedoch begrenzt, ebenso die erzielbaren Abmessungen der Kompaktkörper.In hot pressing (so-called batch process), shear zones are created which, on the one hand, result in the platelets being aligned in the direction of flow and, on the other hand, lead to deformation to a desired shape for the magnets to be produced. The achievable rectified degree of orientation of the nanocrystallites is limited in this method, however, as are the achievable dimensions of the compact bodies.

Eine Erweiterung stellt das sogenannte Rückwärtsfließpressen dar, bei welchem das Material typischerweise aus einem Vollzylinder in einen Hohlzylinder umgeformt wird, dessen Vorzugsrichtung entsprechend der Fließrichtung und auftretender Scherkräfte zu einer gewünschten diametralen Vorzugsrichtung führt.An extension is the so-called backward extrusion, in which the material is typically formed from a solid cylinder into a hollow cylinder, the preferred direction of which leads to a desired diametrical preferred direction in accordance with the direction of flow and the shear forces that occur.

Des Weiteren sind allgemeine Strangpressverfahren bekannt, welche direkt, indirekt oder isostatisch durchgeführt werden.Furthermore, general extrusion processes are known which are carried out directly, indirectly or isostatically.

Die US 2004/0025974 A1 offenbart nanokristalline und Nanokomposit-Seltenerdpermanentmagnetmaterialien und Verfahren zur Herstellung von Magneten. Die Magnetmaterialien können isotrop oder anisotrop sein und weisen keine Seltenerd-reiche Phase auf.The US 2004/0025974 A1 discloses nanocrystalline and nanocomposite rare earth permanent magnet materials and methods of making magnets. The magnetic materials can be isotropic or anisotropic and have no rare earth-rich phase.

Die JP H06 224061 A offenbart ein Herstellungsverfahren zur effizienten Herstellung eines anisotropen Seltenerdmagneten mit hochmagnetischen Eigenschaften mit einer hohen Ausbeute. Die JP H03 14215 A offenbart ein Extrusionsschmelz-Verfahren eines mit Kunststoff gemischten Körpers, der Magnetpulver und einen Binder enthält.
" Extrusion von Metallpulvern durch kontinuierliches Pulverstrangpressen", Claudia Stadelmann, 19.11.2009, Seiten 1 bis 145, XP055077332, Dissertation, Technische Fakultät der Universität Erlangen-Nürnberg offenbart konventionelles Pulverstrangpressen unter Anwendung einer als Konform-Technologie bezeichneten Ausführung. In dem Prozess erfolgt eine Pulverzuführung in eine Greifzone und Stauchzone, wobei dieses Verhalten in einem Umlenkungs- und Vorkammerbereich beschrieben wird.
Schließlich zeigt die US 5 000 796 A ein Verfahren zur Herstellung anisotroper Permanentmagnete durch Extrudieren einer Seltenerdmagnetlegierung unterhalb der Schmelztemperatur der Legierung bei einem Extrusionsverhältnis von 10:1 bis 26:1.
Es ist die Aufgabe der vorliegenden Erfindung, ein Verfahren bereitzustellen, mittels welchem anisotrope Magnete mit einer nanoskaligen Kornstruktur bei einer gleichzeitigen möglichst gleichgerichteten Orientierung der Kristallitachsen hergestellt werden können.The JP H06 224061 A discloses a manufacturing method for efficiently manufacturing an anisotropic rare earth magnet with high magnetic properties with a high yield. The JP H03 14215 A discloses an extrusion melt process of a plastic mixed body containing magnetic powder and a binder.
" Extrusion of metal powders by continuous powder extrusion ", Claudia Stadelmann, November 19, 2009, pages 1 to 145, XP055077332, dissertation, Technical Faculty of the University of Erlangen-Nuremberg discloses conventional powder extrusion using what is known as conforming technology. In the process, powder is fed into a gripping zone and a compression zone, this behavior being described in a deflection and prechamber area.
Finally, the shows US 5,000 796 A. a method of manufacturing anisotropic permanent magnets by extruding a rare earth magnet alloy below the melting temperature of the alloy at an extrusion ratio of 10: 1 to 26: 1.
It is the object of the present invention to provide a method by means of which anisotropic magnets with a nanoscale grain structure can be produced while simultaneously orienting the crystallite axes as uniformly as possible.

Diese Aufgabe wird durch ein Verfahren zum Herstellen eines nanokristalline Korngrössen aufweisenden, anisotropen Magneten mit den Merkmalen des Patentanspruchs 1 gelöst. Vorteilhafte Ausgestaltungen mit zweckmäßigen und nicht-trivialen Weiterbildungen der Erfindung sind in den abhängigen Ansprüchen angegeben.This object is achieved by a method for producing an anisotropic magnet having nanocrystalline grain sizes and having the features of patent claim 1. Advantageous refinements with expedient and non-trivial developments of the invention are specified in the dependent claims.

Der Erfindung liegt die Erkenntnis zugrunde, dass kontinuierliche Pulverstrangpressverfahren besonders gut zur Herstellung anisotroper Magnete geeignet sind. Dabei werden die Pulverplättchen kontinuierlich verarbeitet, indem typischerweise mittels eines Reibrades diese auf bis zu über 500°C erhitzt und dann das dadurch entstehende teigige Material durch eine unmittelbar nach dem Reibrad angeordnete Matrize gepresst wird. Es wird also im Gegensatz zum Stand der Technik ein vollkommen anderes Verfahren zum Herstellen anisotroper Magnete verwendet.
Beim Pulverstrangpressen treten zudem während des Verdichtungsprozesses Wirbelbereiche auf, in denen mit hoher Ausrichtung und Scherung der plättchenartigen Pulver gerechnet werden kann. Dies führt zur Ausrichtung der Kristallitachsen im Pulver, welche zum Aufbau anisotroper (texturierter) Magnete notwendig ist. Damit ist im Vergleich zu anderen Verfahren ein zusätzlicher Bereich für die Scherung verzichtbar.
Zusätzliche Vorteile ergeben sich bei dem erfindungsgemäßen Verfahren durch eine kurze Wärmeeinbringung und damit einer geringen Beeinflussung des Gefüges des herzustellenden anisotropen Magneten. Durch das erfindungsgemäße Verfahren wird eine hohe Ausbringung ermöglicht, wobei kein Pressrest wie bei üblichen Strangpressverfahren anfällt. Ferner kann die Endgeometrie des anisotropen Magneten in einem Prozess hergestellt werden, wobei insbesondere endlose Stränge des anisotropen Magneten hergestellt werden. Ferner bietet das erfindungsgemäße Verfahren ein hohes Energieeinsparungspotential bei einem gleichzeitig hohen Automatisierungsgrad. Durch dieses kontinuierliche Verfahren zur Herstellung von anisotropen texturierten Permanentmagneten aus Magnetpulvern wird eine vorteilhafte nanokristalline Mikrostruktur erzielt, welche eine hohe Koerzitivfeldstärke bei einer gleichzeitig hohen Remanenz ermöglichen.The invention is based on the knowledge that continuous powder extrusion processes are particularly well suited for producing anisotropic magnets. The powder platelets are continuously processed by typically heating them up to over 500 ° C. using a friction wheel and then pressing the resulting doughy material through a die arranged immediately after the friction wheel. In contrast to the prior art, a completely different method for producing anisotropic magnets is used.
In powder extrusion, swirl areas also occur during the compression process, in which high orientation and shear of the flake-like powders can be expected. This leads to the alignment of the crystallite axes in the powder, which is necessary to build up anisotropic (textured) magnets. Compared to other methods, an additional area for shearing is therefore unnecessary.
Additional advantages result in the method according to the invention from a short introduction of heat and thus a slight influence on the structure of the anisotropic magnet to be produced. A high output is made possible by the method according to the invention, with no pressing residue being obtained as in conventional extrusion processes. Furthermore, the end geometry of the anisotropic magnet can be produced in one process, in particular endless strands of the anisotropic magnet being produced. Furthermore, the method according to the invention offers high energy saving potential with a high degree of automation at the same time. Through this continuous process For the production of anisotropic textured permanent magnets from magnetic powders, an advantageous nanocrystalline microstructure is achieved which enables a high coercive force with a high remanence.

In vorteilhafter Ausgestaltung der Erfindung ist es vorgesehen, dass die Pulverplättchen mit einer nanokristallinen Korngröße hergestellt werden. Dies bewirkt, dass die Pulverplättchen eine hohe Koerzitivfeldstärke aufweisen.In an advantageous embodiment of the invention, it is provided that the powder platelets are produced with a nanocrystalline grain size. This causes the powder platelets to have a high coercive field strength.

Gemäß einer weiteren vorteilhaften Ausführungsform der Erfindung ist es vorgesehen, dass die Pulverplättchen durch ein Schmelzschleuderverfahren hergestellt werden. Hierbei wird durch ein sehr schnelles Abkühlen einer Schmelze des Ausgangsmaterials, aus welchem der anisotrope Magnet hergestellt wird, ein Material mit besonderen Eigenschaften hergestellt. Beim Schmelzschleudern wird die Schmelze mittels einer Düse auf ein üblicherweise mit Wasser gekühltes Kupferrad gebracht, wo sie sofort erstarrt. Die Abkühlgeschwindigkeiten betragen hierbei ca. 10.000 bis 1.000.000 Grad pro Sekunde. Durch die hohe Rotationsgeschwindigkeit wird das so erhaltene Band vom Rad abgeschleudert. Durch das Schmelzschleudern können auf besonders einfache Weise Pulverplättchen mit einer nanokristallinen Mikrostruktur durch Unterkühlung in den amorph-nanokristallinen Bereich erzielt werden.According to a further advantageous embodiment of the invention, it is provided that the powder platelets are produced by a melt-spinning process. Here, a material with special properties is produced by a very rapid cooling of a melt of the starting material from which the anisotropic magnet is made. During melt spinning, the melt is brought to a copper wheel, usually cooled with water, by means of a nozzle, where it solidifies immediately. The cooling rates here are approximately 10,000 to 1,000,000 degrees per second. Due to the high rotational speed, the tape thus obtained is thrown off the wheel. Melt spinning allows powder platelets with a nanocrystalline microstructure to be obtained in a particularly simple manner by supercooling into the amorphous-nanocrystalline region.

Eine weitere vorteilhafte Ausführungsform der Erfindung sieht vor, dass als Ausgangsmaterial für die Pulverplättchen Nd2Fe14B verwendet wird. Mit anderen Worten wird also eine Legierung aus Neodym, Eisen und Bor verwendet, welche besonders gute dauermagnetische Eigenschaften aufweist.A further advantageous embodiment of the invention provides that Nd 2 Fe 14 B is used as the starting material for the powder platelets. In other words, an alloy of neodymium, iron and boron is used, which has particularly good permanent magnetic properties.

Ein durch das erfindungsgemäße Verfahren hergestellter anisotroper Magnet ist mittels des erfindungsgemäßen Verfahrens hergestellt. Dadurch weist der Magnet eine nanoskalige Kornstruktur bei einer im Wesentlichen gleichgerichteten Orientierung der Kristallitachsen auf. Dadurch weist der Magnet sowohl eine hohe Koerzitivfeldstärke als auch eine hohe Remanenz auf.An anisotropic magnet produced by the method according to the invention is produced by means of the method according to the invention. As a result, the magnet has one nanoscale grain structure with essentially the same orientation of the crystallite axes. As a result, the magnet has both a high coercive force and a high remanence.

Weitere Vorteile, Merkmale und Einzelheiten der Erfindung ergeben sich aus der nachfolgenden Beschreibung eines bevorzugten Ausführungsbeispiels sowie anhand der Zeichnung.Further advantages, features and details of the invention result from the following description of a preferred exemplary embodiment and from the drawing.

Ausführungsbeispiele der Erfindung werden nachfolgend anhand der Zeichnung näher erläutert. Die Zeichnung zeigt in:

Fig. 1
eine schematische, teilweise geschnittene Ansicht einer Pulverstrangpressanlage, in welche metallische Pulverplättchen eingeführt und zu einem als endlosen Strang ausgebildeten anisotropen Magneten verarbeitet werden;
Fig. 2
eine mikroskopische Aufnahme von den magnetischen Pulverplättchen, welche mittels eines Rascherstarrungsverfahrens hergestellt worden sind; und
Fig. 3
eine mikroskopische Aufnahme des Gefüges des anisotropen Magneten, nachdem dieser mittels der Pulverstrangpressanlage hergestellt worden ist.
Exemplary embodiments of the invention are explained in more detail below with reference to the drawing. The drawing shows in:
Fig. 1
is a schematic, partially sectioned view of a powder extrusion system, into which metallic powder platelets are inserted and processed into an anisotropic magnet formed as an endless strand;
Fig. 2
a micrograph of the magnetic powder platelets which have been produced by means of a rapid solidification process; and
Fig. 3
a microscopic picture of the structure of the anisotropic magnet after it has been produced by means of the powder extrusion system.

Eine Pulverstrangpressanlage 10, mittels welcher aus magnetischen Pulverplättchen 12 ein als Endlosmaterial ausgebildeter anisotroper Magnet 14 hergestellt wird, ist in einer schematischen Schnittansicht in Fig. 1 gezeigt. Beim kontinuierlichen Pulverstrangpressen erfolgt die Zuführung der Pulverplättchen 12 in eine umlaufende, nicht näher bezeichnete Nut eines sich drehenden Extrusionsrades 16. Dabei werden die Pulverplättchen 12 durch Reibung in Bewegungsrichtung, welche durch den Pfeil 18 gekennzeichnet ist, des Extrusionsrades 16 transportiert.A powder extrusion system 10, by means of which an anisotropic magnet 14 formed as an endless material is produced from magnetic powder platelets 12, is shown in a schematic sectional view in FIG Fig. 1 shown. In continuous powder extrusion, the powder platelets 12 are fed into a circumferential, unspecified groove of a rotating extrusion wheel 16. The powder platelets 12 are transported by friction in the direction of movement, which is indicated by the arrow 18, of the extrusion wheel 16.

Ein Teil des Extrusionsrades 16 wird durch einen stationären Werkzeugträger 20 mit einer Mehrzahl von hier nicht näher bezeichneten Werkzeugeinsätzen abgedeckt. Das Extrusionsrad 16 und der Werkzeugträger 20 bilden also eine Extrusionskammer aus, in welcher die zugefügten Pulverplättchen 12 durch Reibung und Scherung erwärmt werden. Mit dem Erreichen der Fließgrenze der Pulverplättchen 12 erfolgt die Extrusion durch eine Matrize 22 radial zum Extrusionsrad 16. Eine Greifzone 24, in welcher die Pulverplättchen 12 in der Bewegungsrichtung 18 transportiert werden sowie eine Stauchzone 26, in welcher die magnetischen Pulverplättchen 12 verdichtet und durch Reibung und Scherung erwärmt werden, sind zusätzlich in der Fig. 1 gezeigt.A part of the extrusion wheel 16 is covered by a stationary tool carrier 20 with a plurality of tool inserts, not shown here. The extrusion wheel 16 and the tool carrier 20 thus form an extrusion chamber in which the added powder platelets 12 are heated by friction and shear. When the yield point of the powder platelets 12 is reached, the extrusion takes place radially through the die 22 to the extrusion wheel 16. A gripping zone 24 in which the powder platelets 12 are transported in the direction of movement 18 and a compression zone 26 in which the magnetic powder platelets 12 are compressed and by friction and are heated in addition to the shear Fig. 1 shown.

Vor dem Zuführen der Pulverplättchen 12 werden diese mittels eines Rascherstarrungsverfahrens hergestellt. Im vorliegenden Fall werden die Pulverplättchen 12 durch ein Schmelzschleuderverfahren hergestellt. Als Ausgangsmaterial für die magnetischen Pulverplättchen 12 wird dabei eine Legierung aus Neodym, Eisen und Bor mit der Zusammensetzung Nd2Fe14B verwendet, welches zunächst aufgeschmolzen und mittels einer Düse auf ein üblicherweise mit Wasser gekühltes Kupferrad gebracht wird, wo es sofort erstarrt. Durch eine entsprechend hohe Rotationsgeschwindigkeit des Kupferrades wird das so erhaltene Band von dem Rad abgeschleudert. Durch Zerkleinerung des erhaltenen Bandes werden die magnetischen Pulverplättchen 12 erhalten.Before the powder flakes 12 are fed in, they are produced by means of a rapid solidification process. In the present case, the powder platelets 12 are produced by a melt-spinning process. An alloy of neodymium, iron and boron with the composition Nd 2 Fe 14 B is used as the starting material for the magnetic powder platelets 12, which is first melted and placed on a copper wheel, which is usually cooled with water, where it immediately solidifies. The tape obtained in this way is thrown off the wheel by a correspondingly high rotational speed of the copper wheel. The magnetic powder flakes 12 are obtained by comminuting the tape obtained.

In Fig. 2 ist das nanokristalline Korngrößen aufweisende Korngefüge der mittels des Schmelzschleuderverfahrens hergestellten magnetischen Pulverplättchen 12 gezeigt. Die Pulverplättchen 12 weisen eine Länge von üblicherweise einigen wenigen hundert Mikrometern auf. Wie aus der Abbildung zu erkennen ist, weisen Nanokristallite 28, aus welchen die magnetischen Pulverplättchen 12 ausgebildet sind, noch keine einheitliche Ausrichtung in Form einer magnetokristallinen Vorzugsrichtung auf.In Fig. 2 the nanocrystalline grain size of the magnetic powder flakes 12 produced by means of the melt-spinning process is shown. The powder platelets 12 usually have a length of a few hundred micrometers. As can be seen from the figure, nanocrystallites 28 from which the magnetic powder platelets 12 are formed do not yet have a uniform orientation in the form of a magnetocrystalline preferred direction.

Erst durch Hinzufügen der Pulverplättchen 12 zu der Pulverstrangpressanlage und Verpressen dieser Pulverplättchen 12 zu dem als Endlosmaterial ausgebildeten anisotropen Magneten 14 erfolgt die Herstellung eines kompakt ausgebildeten Magneten 14, bei welchem die Nanokristallite 28 eine im Wesentlichen gleichgerichtete Orientierung ihrer jeweiligen Kristallitachsen aufweisen. Die Herstellung der anisotropen Magneten 14 erfolgt also in einem einzigen Umformschritt aus den als nanokristallinen Pulver ausgebildeten magnetischen Pulverplättchen 12.It is only by adding the powder platelets 12 to the powder extrusion system and pressing these powder platelets 12 to the anisotropic magnet 14, which is designed as an endless material, that a compact magnet 14 is produced, in which the nanocrystallites 28 have an essentially uniform orientation of their respective crystallite axes. The anisotropic magnets 14 are thus produced in a single forming step from the magnetic powder platelets 12 in the form of nanocrystalline powder.

Durch die Herstellung der magnetischen Pulverplättchen 12 mittels des Schmelzschleuderverfahrens und dem anschließenden Zuführen der Pulverplättchen 12 zu der Pulverstrangpressanlage 10 und der Herstellung der anisotropen Magneten 14 werden also kompakte Magnete 14 mit einer im Wesentlichen gleichen Orientierung der Kristallitachsen der jeweiligen Nanokristallite 28 erreicht.By producing the magnetic powder platelets 12 by means of the melt-spinning process and then feeding the powder platelets 12 to the powder extrusion system 10 and producing the anisotropic magnets 14, compact magnets 14 are thus achieved with an essentially identical orientation of the crystallite axes of the respective nanocrystallites 28.

Infolge dessen werden anisotrope Magneten 14 mit einer hohen Remanenz und einer hohen Koerzitivfeldstärke auf besonders einfache und kostengünstige Weise hergestellt. Insbesondere das Pulverstrangpressen zeichnet sich durch eine kurze Prozesskette mit einem hohen Automatisierungsgrad aus. Die Umformung zur Endgeometrie erfolgt in einem einzigen Arbeitsschritt, wodurch entsprechende Energieeinsparungen durch einen Entfall weiterer Umformschritte erzielbar sind. Ferner kann der Einsatz von Schmiermitteln entfallen und des Weiteren besteht eine nur relativ kurze Wärmeinwirkzeit auf das Material, so dass sich keine unerwünschten GefügeÄnderungen einstellen.As a result, anisotropic magnets 14 with a high remanence and a high coercive force are produced in a particularly simple and inexpensive manner. In particular, powder extrusion is characterized by a short process chain with a high degree of automation. The shaping to the final geometry takes place in a single work step, whereby corresponding energy savings can be achieved by eliminating further shaping steps. Furthermore, the use of lubricants can be dispensed with and there is also only a relatively short heat exposure time on the material, so that no undesired structural changes occur.

Claims (5)

  1. Method for producing an anisotropic magnet (14) having nanocrystalline grain sizes, comprising the steps of:
    - producing magnetic powder platelets (12) by means of a rapid solidification process;
    - feeding the powder platelets (12) to a powder extrusion installation (10);
    - powder-extruding the anisotropic magnet (14) from the powder platelets (12) by means of the powder extrusion installation (10),
    wherein
    - the powder extrusion is continuous,
    characterized in that
    an extrusion wheel (16) and a platen (20) of the powder extrusion installation (10) form an extrusion chamber, in which the added powder platelets (12) are heated by friction and shearing.
  2. Method according to Claim 1, characterized in that, when the yield point of the powder platelets (12) is reached, the extrusion takes place through a die (22) radially with respect to the extrusion wheel (16).
  3. Method according to Claim 1 or 2, characterized in that the extrusion chamber has a gripping zone (24), in which the powder platelets (12) are transported in a direction of movement (18), and an upsetting zone (26), in which the magnetic powder platelets (12) are compacted and heated by friction and shearing.
  4. Method according to Claim 1, 2 or 3, characterized in that the powder platelets (12) are produced by a melt spinning process.
  5. Method according to one of the preceding claims, characterized in that Nd2Fe14B is used as a feedstock for the powder platelets (12).
EP13745634.9A 2012-09-18 2013-08-02 Method of manufacturing an anisotropic magnet Active EP2877999B1 (en)

Applications Claiming Priority (2)

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DE102012216668.8A DE102012216668A1 (en) 2012-09-18 2012-09-18 Method of making an anisotropic magnet and anisotropic magnet
PCT/EP2013/066258 WO2014044456A1 (en) 2012-09-18 2013-08-02 Method for producing an anisotropic magnet, and anisotropic magnet

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EP2877999B1 true EP2877999B1 (en) 2020-03-11

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5000796A (en) * 1988-02-23 1991-03-19 Eastman Kodak Company Anisotropic high energy magnets and a process of preparing the same
EP2767987A1 (en) * 2011-10-11 2014-08-20 Toyota Jidosha Kabushiki Kaisha Sintered body of rare-earth magnet precursor, and manufacturing method for fine magnetic powder for forming sintered body

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0314215A (en) * 1989-06-13 1991-01-22 Tokin Corp Manufacturing process and device for magnetic anisotropical magnet
JPH06224061A (en) * 1993-01-23 1994-08-12 Ii R D:Kk Manufacture of anisotropic rare-earth magnet
US20040025974A1 (en) * 2002-05-24 2004-02-12 Don Lee Nanocrystalline and nanocomposite rare earth permanent magnet materials and method of making the same

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5000796A (en) * 1988-02-23 1991-03-19 Eastman Kodak Company Anisotropic high energy magnets and a process of preparing the same
EP2767987A1 (en) * 2011-10-11 2014-08-20 Toyota Jidosha Kabushiki Kaisha Sintered body of rare-earth magnet precursor, and manufacturing method for fine magnetic powder for forming sintered body

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WO2014044456A1 (en) 2014-03-27
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