EP3280558A1 - Verfahren zur herstellung eines weichmagnetischen körpers - Google Patents
Verfahren zur herstellung eines weichmagnetischen körpersInfo
- Publication number
- EP3280558A1 EP3280558A1 EP16715832.8A EP16715832A EP3280558A1 EP 3280558 A1 EP3280558 A1 EP 3280558A1 EP 16715832 A EP16715832 A EP 16715832A EP 3280558 A1 EP3280558 A1 EP 3280558A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- soft magnetic
- coating
- powder particles
- sintering
- coating material
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000004519 manufacturing process Methods 0.000 title description 9
- 238000000576 coating method Methods 0.000 claims abstract description 103
- 239000011248 coating agent Substances 0.000 claims abstract description 100
- 239000000843 powder Substances 0.000 claims abstract description 88
- 239000000463 material Substances 0.000 claims abstract description 79
- 239000002245 particle Substances 0.000 claims abstract description 72
- 238000000034 method Methods 0.000 claims abstract description 65
- 238000005245 sintering Methods 0.000 claims abstract description 58
- 239000000696 magnetic material Substances 0.000 claims abstract description 43
- 238000010438 heat treatment Methods 0.000 claims abstract description 41
- 238000002844 melting Methods 0.000 claims abstract description 17
- 230000008018 melting Effects 0.000 claims abstract description 17
- 239000006247 magnetic powder Substances 0.000 claims abstract description 15
- 230000005291 magnetic effect Effects 0.000 claims description 49
- 230000008569 process Effects 0.000 claims description 23
- 239000011159 matrix material Substances 0.000 claims description 19
- 239000007858 starting material Substances 0.000 claims description 15
- 238000003825 pressing Methods 0.000 claims description 7
- 238000000151 deposition Methods 0.000 claims description 5
- 230000005292 diamagnetic effect Effects 0.000 claims description 3
- 239000000126 substance Substances 0.000 claims description 3
- 238000007669 thermal treatment Methods 0.000 claims description 3
- 238000000469 dry deposition Methods 0.000 claims description 2
- 239000011810 insulating material Substances 0.000 claims description 2
- 230000005298 paramagnetic effect Effects 0.000 claims description 2
- 239000011521 glass Substances 0.000 description 15
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
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- 238000005240 physical vapour deposition Methods 0.000 description 4
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- 238000001704 evaporation Methods 0.000 description 3
- 230000001965 increasing effect Effects 0.000 description 3
- 238000002955 isolation Methods 0.000 description 3
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- 229910052760 oxygen Inorganic materials 0.000 description 3
- 229910052698 phosphorus Inorganic materials 0.000 description 3
- 239000002243 precursor Substances 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- 229910000859 α-Fe Inorganic materials 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 229910000975 Carbon steel Inorganic materials 0.000 description 2
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 2
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000005294 ferromagnetic effect Effects 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 239000006249 magnetic particle Substances 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 239000002907 paramagnetic material Substances 0.000 description 2
- 239000011574 phosphorus Substances 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- FRWYFWZENXDZMU-UHFFFAOYSA-N 2-iodoquinoline Chemical compound C1=CC=CC2=NC(I)=CC=C21 FRWYFWZENXDZMU-UHFFFAOYSA-N 0.000 description 1
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- 229910052580 B4C Inorganic materials 0.000 description 1
- 229910052582 BN Inorganic materials 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- 235000008733 Citrus aurantifolia Nutrition 0.000 description 1
- 229910015372 FeAl Inorganic materials 0.000 description 1
- -1 FeAlSi Inorganic materials 0.000 description 1
- 229910002546 FeCo Inorganic materials 0.000 description 1
- 229910002555 FeNi Inorganic materials 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 229910017706 MgZn Inorganic materials 0.000 description 1
- 229910003962 NiZn Inorganic materials 0.000 description 1
- 229910004283 SiO 4 Inorganic materials 0.000 description 1
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 1
- 235000011941 Tilia x europaea Nutrition 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 229910052790 beryllium Inorganic materials 0.000 description 1
- LTPBRCUWZOMYOC-UHFFFAOYSA-N beryllium oxide Inorganic materials O=[Be] LTPBRCUWZOMYOC-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 1
- 239000005388 borosilicate glass Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000002734 clay mineral Substances 0.000 description 1
- 238000009694 cold isostatic pressing Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 239000005331 crown glasses (windows) Substances 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000005137 deposition process Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000007723 die pressing method Methods 0.000 description 1
- 238000000113 differential scanning calorimetry Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005566 electron beam evaporation Methods 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 239000003302 ferromagnetic material Substances 0.000 description 1
- 239000005329 float glass Substances 0.000 description 1
- 239000002223 garnet Substances 0.000 description 1
- 239000006112 glass ceramic composition Substances 0.000 description 1
- 230000009477 glass transition Effects 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000007731 hot pressing Methods 0.000 description 1
- 150000004678 hydrides Chemical class 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000001939 inductive effect Effects 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 229910052909 inorganic silicate Inorganic materials 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 238000010849 ion bombardment Methods 0.000 description 1
- 238000010884 ion-beam technique Methods 0.000 description 1
- 229910052745 lead Inorganic materials 0.000 description 1
- 239000004571 lime Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 230000005415 magnetization Effects 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 229910003465 moissanite Inorganic materials 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 229910052574 oxide ceramic Inorganic materials 0.000 description 1
- 239000011224 oxide ceramic Substances 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 230000010287 polarization Effects 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000004071 soot Substances 0.000 description 1
- 229910052596 spinel Inorganic materials 0.000 description 1
- 239000011029 spinel Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000002207 thermal evaporation Methods 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000004634 thermosetting polymer Substances 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 238000012800 visualization Methods 0.000 description 1
- 239000003039 volatile agent Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/08—Metallic powder characterised by particles having an amorphous microstructure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/14—Treatment of metallic powder
- B22F1/142—Thermal or thermo-mechanical treatment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/16—Metallic particles coated with a non-metal
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/02—Compacting only
-
- 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
- B22F3/10—Sintering only
-
- 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
- H01F1/33—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 mixtures of metallic and non-metallic particles; metallic particles having oxide skin
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/255—Magnetic cores made from particles
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/08—Cores, Yokes, or armatures made from powder
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
-
- 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
- B22F2203/00—Controlling
- B22F2203/11—Controlling temperature, temperature profile
-
- 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
Definitions
- the present invention relates to a method for producing a soft magnetic body. Furthermore, the invention relates to a soft magnetic body and to a soft magnet having a soft magnetic body.
- soft magnetic bodies and soft magnets made of soft magnetic materials for the manufacture and use of soft magnetic cores of electric motors, electric valves in injection systems, actuators and sensors or the like.
- Such soft magnetic body z. B. be formed as toroidal cores, ground cores or powder cores.
- the soft magnetic core consists of a powder composite material.
- the powder composite is prepared by mixing a ferromagnetic amorphous or nanocrystalline alloy powder with a ferromagnetic dielectric powder and a thermoplastic or thermosetting polymer.
- the disadvantage is that the production of known soft magnetic body or soft magnets made of a soft magnetic body is often very expensive and expensive. Also, the robustness of the soft magnetic body is often reduced, the temperature and / or corrosion resistance may not be sufficient. In an operation of the soft magnetic body or soft magnets or electric sheets in an alternating magnetic field - especially at higher frequencies - the soft magnetic body often have a high power loss due to the occurrence of eddy currents. It creates high temperatures, which have a negative impact on operation and reliability. Furthermore, during the production process, in particular by the powder metallurgical route (during sintering), undesired or uncontrollable crystal growth of the particles of the soft magnetic material takes place typically.
- a further object is the reduction of the energy losses arising in the soft magnet.
- a soft magnetic body is understood in particular to be a body made of a soft magnetic material and / or a soft magnetic material.
- the body may preferably have a specific design and thus be formed, for example, as a toroidal core, ground core, powder core and / or as a molded or solid part.
- a soft magnet is also understood to mean, in particular, a soft magnetic body which has a low coercive field strength and is therefore unsuitable for use as a permanent magnet or permanent magnet.
- the soft magnet or the soft magnetic body has the soft magnetic material which can be easily magnetized (magnetic polarization) in a magnetic field, for example, as a ferromagnetic material and thus serves to "amplify" the magnetic field
- magnetisation does not last for a long time, so that after the omission of the magnetic field there is no significant magnetization, the coercitive field strength of a soft magnetic material is therefore substantially lower than that of a hard magnetic material.
- the object is achieved in particular by a method for producing a soft-magnetic body and in particular a soft magnet, comprising the following steps:
- the powder particles b) coating the powder particles with an insulating (ie electrically non-conductive), in particular thermally stable coating material.
- the sintering temperature of the coating material is lower than the sintering temperature of the soft magnetic material.
- step c) The steps are preferably carried out sequentially, in particular step c) being carried out after step b).
- the temperature increase resulting from the heat treatment relates in particular to the coated powder, ie the temperature increase takes place both for the coating material and for the powder particles.
- the heat treatment in particular both the coating material and the soft magnetic material maximum one used for heat treatment process temperature.
- a heat treatment of the powder particles coated in step b) takes place, wherein preferably only the coating material according to step c) is sintered or vitrified.
- the term sintering temperature refers to a temperature suitable for sintering and / or vitrification (ie conversion into the glass phase) of the respective material (ie the soft magnetic material or the coating material).
- the sintering temperature is, for example, in a range below the transformation temperature (in particular also glass transition temperature) or the melting temperature of the respective material. It is further conceivable that the sintering temperature is substantially proportional to the melting temperature and / or transformation temperature and / or a solidus temperature of the respective material.
- the transformation temperature of the coating material is lower than the melting temperature or sintering temperature of the soft magnetic material in order to prevent sintering or melting of the powder particles.
- the coating material is preferably thermally stable at up to 600 ° C (Celsius) and / or up to 800 ° C and / or up to 1200 ° C and / or up to 1400 ° C.
- step b) is preferably such a coating material chosen that the adjacent powder particles can not grow together in step b) or step c) by the heat treatment.
- the method according to the invention which is in particular a powder metallurgy method, the corrosion resistance of the soft magnetic body is increased due to the coating.
- a passivation of the particle surfaces As a result, impurities such.
- the isolation of the powder particles by the coating material also allows the formation of an insulating, ie electrically non-conductive barrier.
- the coating material serves this particular as an insulator or binder, which z. B. is formed from a starting material and / or used to produce a matrix material.
- the starting material in this sense preferably represents a precursor for the coating material and / or the coating material is a precursor for the matrix material.
- the process temperature used for the heat treatment or sintering is preferably chosen such that the coating material is incorporated into a matrix (a diamagnetic) or paramagnetic material) that embeds the powder particles.
- the heat treatment or sintering of the coating material or the entire process according to the invention takes place here under conditions in which no sintering of the soft magnetic material takes place.
- eddy current losses can be significantly reduced and a rise in temperature or a heating of the soft magnet can be reduced during operation with higher frequency alternating magnetic fields.
- further energy losses such as hysteresis or repercussion losses, due to the insulating effect of the coating can be reduced.
- Sintered powder particles thus isolated have high temperature stability against soft magnetic components mixed together with a polymer as a binder.
- a post-treatment in particular a further heat treatment and / or a shaping of the heat-treated powder, can take place.
- the heat treatment of the coating material according to step c) corresponds in particular to a heat treatment of the entire powder or of the powder particles with the aim of sintering the coating material, although the melting and / or sintering of the powder particles and / or the soft magnetic material avoided and / or prevented becomes. This allows adaptation of the soft magnet produced for a wide variety of uses.
- the soft magnetic powder is previously produced.
- the powder may in particular be crystalline soft magnetic materials (such as soft iron, carbon steels, FeAl, FeAlSi, FeNi, FeCo or the like alloys) and / or amorphous soft magnetic materials (such as FeNiBSi, FeBSi or the like) and / or soft magnetic ferrite materials (eg MnZn ferrites, MgZn ferrites or the like), spinel materials (eg MnMgZn, NiZn or the like) and / or garnet materials (BiCa, YGd or the like) and / or the like.
- crystalline soft magnetic materials such as soft iron, carbon steels, FeAl, FeAlSi, FeNi, FeCo or the like alloys
- amorphous soft magnetic materials such as FeNiBSi, FeBSi or the like
- soft magnetic ferrite materials eg MnZn ferrites, MgZn ferrites or the like
- spinel materials eg M
- the coated powder particles are shaped into a compact, in particular by pressing.
- the advantage is achieved that reliably the desired shape of the soft magnetic body, the properties of the material and the packing density can be adjusted or improved.
- the term "compact” here refers generally to the resulting shaped body or green body and is thus not limited to pressing, for example by molding and / or pressing and / or pouring and / or die pressing and / or hot pressing and / or cold isostatic pressing and / or hot isostatic pressing and / or ultrasonic pressing or the like .
- the coated powder particles result from the uncoated powder particles, which were coated according to step b) and thus have powder particles coated by the coating material. so that the molding can optionally be carried out together with the sintering and / or the heat treatment according to step c) . This affords the advantage that the temperature required for sintering can be reduced, but then it has to be taken into account that for sintering respectively.
- process temperature is adjusted so that the lower sintering temperature of the soft magnetic material is not achieved in the heat treatment.
- the heating of the compact is carried out according to step c), for example, up to a temperature below the melting temperature of the soft magnetic material, but at least to a temperature which sinters the coating material and / or transferred to the glass phase, ie vitrified.
- the process temperature for heat treatment according to step c) is in particular in the transformation region of the coating material, in particular glass (if this is used as a coating material).
- the heat treatment according to step c) can be carried out in vacuo or in a neutral or a reducing atmosphere.
- the heat treatment and in particular the sintering under air and / or nitrogen and / or argon and / or hydrogen can take place, since the surface of the powder particles is passivated.
- the process temperature and / or the sintering temperature of the coating material is at least 50 K (Kelvin) and / or 100 K and / or 150 K and / or 200 K and / or 220 K below the sintering temperature of the soft magnetic material.
- a process temperature used for the heat treatment, in particular for sintering, and / or a process pressure used for the heat treatment are adapted such that sintering and / or melting of the powder particles is avoided
- the process temperature is below the sintering temperature suitable for sintering the soft magnetic material.
- the heat treatment is preferably carried out, ie in particular sintering and / or vitrification, in such a way that the process temperature used and the process pressure together influence the sintering temperature.
- the compact or the coating material is heated to a maximum of one process temperature, wherein in this process the maximum process pressure is selected such that sintering and / or melting of the powder particles and / or the soft magnetic material is always avoided and / or prevented.
- the heat treatment is preferably carried out in such a way that a phase transition of the powder particles is always avoided. As a result, a substantial change of the powder particles (crystal growth or contact closure) is prevented, whereby the performance of the soft magnet is increased.
- the coating material at least partially in a matrix (ie a matrix material) of a diamagnetic and / or paramagnetic, in particular insulating material is transferred, in particular such that the matrix embeds the powder particles.
- a coating of the coating material or of the matrix material forms, which completely surrounds the powder particles (that is, in particular the predominant number of the powder particles of the powder), for example.
- the coating increases the corrosion resistance of the soft magnetic material.
- the coating leads to a passivation of the particle surfaces of the powder particles. Thus, impurities such.
- the coating by the coating material takes place in particular such that forms a non-conductive barrier, which leads to an isolation of the powder particles. As a result, eddy currents can be significantly reduced and reduce the unwanted heating of the soft magnetic body at higher frequency alternating magnetic fields.
- the coating is carried out by a dry deposition method, in particular by a chemical and / or physical gas deposition method.
- the coating can be carried out by chemical vapor deposition (CVD) or physical vapor deposition (PVD).
- CVD chemical vapor deposition
- PVD physical vapor deposition
- the deposition process in particular a starting material for. B. the starting material used to produce the coating material.
- Physical vapor deposition processes ie PVD are understood to mean vacuum-based coating processes in which the starting material is converted into the gas phase and deposited on the substrate to be coated (ie the powder particles). For example, is deposited by way of condensation.
- evaporation processes such as thermal evaporation, laser beam evaporation, arc evaporation, electron beam evaporation
- sputtering ie sputter deposition or cathode sputtering
- CVD chemical vapor deposition
- the starting material is transferred by various techniques in the gas phase, in which case, if necessary, electron or ion beams are used for the deposition.
- the deposition of the coating material on the surface of the substrate due to a chemical reaction of the component present in the gas phase) takes place to form a solid component.
- the starting material is thus in a volatile form in the gas phase and precipitates as a less volatile compound, for example elementally or as an oxide.
- the dry process have the advantage that no expensive solvents are needed and no measures for solvent disposal or solvent recovery are required.
- energy-intensive drying processes are eliminated, so that the coating methods described have a high degree of flexibility with regard to the applicable coating materials.
- nasal techniques such as sol-gel coating can be used.
- the coating may preferably have at least one or an additional oxide layer and be produced in particular by the oxidation of the powder and subsequent coating by glass and / or ceramic glass and / or ceramic. This results in a particularly advantageous embodiment and isolation of the soft magnetic powder particles.
- the energy losses arising in the soft magnet due to the electrical insulation effect of the coating can be reduced in conjunction with the individual particles, so that no short circuit of individual soft magnetic particles.
- the coating material is obtained in particular from a starting material and after coating, the coating material, in particular in oxidic and / or fine particulate structure, is present, wherein preferably by heat treatment and / or sintering, the coating material is vitr .
- vitrification refers to the solidification of a liquid by increasing the viscosity while it is being cooled.
- a crystallization remains and there is an amorphous material.
- the starting material in particular is used as starting material. From the starting material, for example, the coating material and from the Coating material generates the matrix material (matrix).
- the materials, in particular the matrix material may preferably comprise and / or consist of glass, a glass ceramic and / or a ceramic.
- the materials used for the coating, ie the coating material and / or the starting material and / or the matrix material may further comprise and / or consist of di- or paramagnetic materials, in particular glass materials and / or glass ceramics and / or ceramics and / or oxides and / or mixtures of the materials mentioned.
- the matrix material can be a glass and / or a glass ceramic and / or a ceramic and / or a combination of the materials mentioned.
- the material used for the coating comprises in particular SiO 2 and / or other metal oxides, in particular Al 2 O 3, Na 2 O, K 2 O, MgO, CaO, B 2 O 3, CO 2, PbO and / or the like, and particularly preferably quartz and / or crown glass and / or lime.
- the materials may optionally have mixtures of different oxides with variable SiO 2 content.
- the oxides in the glass may not be in the form of separate low molecular weight molecules but as extended networks. So is z.
- Ceramic materials include, in particular, mineral silicate materials, ie, such as the glasses or glass ceramics, SiO 2 or SiO 4-based materials, such as kaolins or clay minerals, and / or oxide ceramics based on aluminum oxide, beryllium oxide or the like. Furthermore, the ceramic materials may also comprise non-oxidic materials and / or carbides and / or nitrides, such as silicon carbide SiC, boron carbide BC or boron nitride BN. It is also conceivable to make distinctions between the chemical composition of the ceramic materials and the glasses or glass ceramics.
- the transformation temperature or melting temperature can be determined, for example, by calorimetric methods (such as differential scanning calorimetry or DCS).
- the transformation temperature and / or melting temperature of the matrix material is preferably chosen to be at least 100 K and preferably at least 200 K below the melting temperature of the soft magnetic material.
- salts and / or volatile compounds such as hydrides are used for the production of the glasses, glass ceramics and / or ceramics.
- the corresponding elemental components which may still be formed in the gas phase or after Deposition on the particle surface of the powder particles to the corresponding oxides react.
- step b) ie after the coating
- step c) ie after sintering or heat treatment
- a thermal aftertreatment takes place in particular by hot isostatic pressing.
- the hot isostatic pressing can alternatively or additionally also take place simultaneously with step c).
- the compact is, for example, in the compression space of the plant or optionally also z. B. set in a deformable container, which z. B. to a heat treatment temperature, which may be low or higher than the sintering temperature is heated.
- the compact is subjected to a pressure of up to 50 MPa and / or 100 MPa and / or 200 MPa and / or 300 MPa.
- a magnetic field treatment and / or a thermal treatment can take place.
- a soft magnetic body comprising:
- Powder particles, in particular cores, of a soft magnetic material are provided.
- Coating (especially the cores) of a heat-treated insulating coating material, wherein the coating surrounds the powder particles.
- the soft-magnetic body is produced in particular in such a way by the method according to the invention that the production always takes place without magnetic field (ie no external magnetic field is used).
- the core in this case preferably has a diameter which essentially corresponds to the diameter of the powder particles in step a), d. H. before the heat treatment, preferably in the range of 0.5 ⁇ to 250 ⁇ (depending on the material and intended use of the body).
- the soft magnetic body according to the invention brings about the same advantages as have been described in detail with reference to a method according to the invention.
- the soft magnetic body may preferably be produced by a method according to the invention.
- a layer thickness of the coating is in the range of 1 nm to 10 ⁇ m, preferably in the range of 2 nm and 50 nm.
- the diameter of the powder particles before sintering according to step c) substantially corresponds to the diameter of the powder particles after sintering according to step c) and / or the diameter of the powder particles of the soft magnetic body according to the invention or of the soft magnet according to the invention. The diameter remains substantially constant, in particular during the entire process according to the invention, if appropriate with a certain distribution (or tolerance).
- the layer thicknesses and diameters are preferably matched to one another such that sufficient electrical insulation and passivation of the powder particles is ensured, wherein the layer thicknesses must be small enough so as not to restrict the magnetic field density of the soft magnet too much.
- the soft magnet has a soft magnetic body according to the invention and / or is produced by a method according to the invention.
- the soft magnet may optionally be produced by further post-treatment steps and / or by an exciting manufacturing process (such as cutting and grinding).
- an exciting manufacturing process such as cutting and grinding.
- Fig. 1 is a schematic representation of an uncoated, soft magnetic powder in
- Fig. 3 is a schematic representation of a coated soft magnetic powder with
- 4 shows a schematic representation of a coated soft magnetic powder in irregular form
- 5 is a schematic representation of a compact of a regular, spherical and coated powder
- Fig. 6 is a schematic representation of a compact of an irregular, coated
- Fig. 8 is a schematic representation of a heat treated, irregular, coated
- FIG. 10 shows a schematic illustration of exemplary embodiments of a soft-magnetic body according to the invention and soft magnets according to the invention.
- a soft magnetic powder 20 may comprise a plurality of powder particles 21, which are formed for example as a spherical and / or ellipsoid of revolution and / or irregular with any shape ( Figure 2).
- the powder particles 21 each have a diameter P of substantially 1 ⁇ to 250 ⁇ . In particular, it is conceivable that the diameters P of the individual powder particles 21 vary at most in this range mentioned and / or in a range of at most 0.1 ⁇ m to 50 ⁇ m.
- the powder particles 21 have a soft magnetic material 22, which z. B. may have a crystalline soft magnetic material such as soft iron or carbon steels.
- the powder particles 21 shown in FIGS. 1 and 2 correspond to uncoated powder particles 21, so that this is an uncoated powder 20a.
- FIGS. 3 and 4 show a coated powder 20b which has a coating material 31.
- the coating material 31 surrounds the powder particles 21 (or cores) as coating 30, the coating 30 having a layer thickness D of at least 1 nm and / or at most 10 nm and / or at most 1 ⁇ and / or at most 10 ⁇ with a tolerance of at most 1 nm and / or 10 nm. It is clearly evident that due to the coating 30, the powder particles 21 are isolated from each other (electrically), whereby eddy current losses can be significantly reduced.
- Figures 5 and 6 show schematically each a compact 40, which has the coated powder 20b.
- the compact is formed, for example, by molding and in particular pressing to obtain a desired shape. The molding or pressing can also be done simultaneously to a heat treatment of the compact. By the heat treatment, in particular by sintering the coated powder 20b or the coating 30, vitrification of the coating material 31 is effected in particular.
- a soft-magnetic body 10 according to the invention is shown (virtually a cut-out after sintering), which has been produced by the method 100 according to the invention.
- the coating material 31 was converted into a matrix material or a matrix 32.
- no significant grain growth has occurred since the process temperature during the heat treatment is below a sintering temperature of the soft magnetic material 22.
- the powder particles 21 have in this case been isolated from one another by an amorphous phase, wherein a contact closure between powder particles is excluded.
- FIG. 9 schematically illustrates method steps of a method 100 according to the invention.
- provision of a soft magnetic powder 20 takes place.
- the soft magnetic powder 20 has powder particles 21 made of a soft magnetic material 22.
- the soft magnetic powder 20 is produced from crystalline, soft-magnetic materials.
- coating of the powder particles 21 with a coating material 31 takes place.
- a coating material 31 and / or a starting material is produced and / or provided.
- the coated powder 20b is pressed to form a compact 40.
- the coated powder 20b or the compact 40 is then heat-treated or sintered, the process temperature used for the heat-treatment being below a sintering temperature of the soft-magnetic material 22.
- the heat treatment is carried out in particular such that a crystal growth of the powder particles 21 is avoided.
- the coating 30 ensures that adjacent powder particles 21 can not grow together.
- an after-treatment eg. B. a hot isostatic pressing.
- a soft magnetic body 10 and a soft magnet 1 1 is shown, which can be used for example for electric motors.
- the desired shape can be achieved, for example, by molding and / or after treatment, which z. B. can be done during sintering or after sintering.
- the soft-magnetic body 10 according to the invention and / or the soft magnet 11 according to the invention can have arbitrary shapes depending on the intended use and is therefore not limited to the shapes shown.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Crystallography & Structural Chemistry (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Dispersion Chemistry (AREA)
- Mechanical Engineering (AREA)
- Soft Magnetic Materials (AREA)
- Powder Metallurgy (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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DE102015105431.0A DE102015105431A1 (de) | 2015-04-09 | 2015-04-09 | Verfahren zur Herstellung eines weichmagnetischen Körpers |
PCT/EP2016/057539 WO2016162383A1 (de) | 2015-04-09 | 2016-04-06 | Verfahren zur herstellung eines weichmagnetischen körpers |
Publications (2)
Publication Number | Publication Date |
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EP3280558A1 true EP3280558A1 (de) | 2018-02-14 |
EP3280558B1 EP3280558B1 (de) | 2020-11-04 |
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EP16715832.8A Active EP3280558B1 (de) | 2015-04-09 | 2016-04-06 | Verfahren zur herstellung eines weichmagnetischen körpers |
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Country | Link |
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EP (1) | EP3280558B1 (de) |
CN (1) | CN107396630B (de) |
DE (1) | DE102015105431A1 (de) |
WO (1) | WO2016162383A1 (de) |
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DE102017210941A1 (de) * | 2017-06-28 | 2019-01-03 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. | Verfahren zum Herstellen eines weichmagnetischen Kompositwerkstoffs und weichmagnetischer Kompositwerkstoff |
DE102021109597A1 (de) * | 2021-04-16 | 2022-10-20 | Magnetec Gmbh | Magnetfeldempfindliches Bauelement, Herstellverfahren und Verwendung |
US20230260687A1 (en) * | 2022-02-14 | 2023-08-17 | General Electric Company | Dual phase soft magnetic particle combinations, components and manufacturing methods |
Family Cites Families (13)
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JPH0744099B2 (ja) * | 1985-04-19 | 1995-05-15 | 鐘淵化学工業株式会社 | 軟質磁性材料組成物 |
JPH10212503A (ja) * | 1996-11-26 | 1998-08-11 | Kubota Corp | 非晶質軟磁性合金粉末成形体及びその製造方法 |
DE19849781A1 (de) * | 1998-10-28 | 2000-05-11 | Vacuumschmelze Gmbh | Spritzgegossener weichmagnetischer Pulververbundwerkstoff und Verfahren zu seiner Herstellung |
JP2001073062A (ja) * | 1999-09-09 | 2001-03-21 | Kubota Corp | 非晶質軟磁性合金粉末成形体の製造方法 |
JP3986043B2 (ja) * | 2001-02-20 | 2007-10-03 | 日立粉末冶金株式会社 | 圧粉磁心及びその製造方法 |
DE10110341A1 (de) * | 2001-03-03 | 2002-10-31 | Bosch Gmbh Robert | Metallpulver-Verbundwerkstoff und Ausgangsmaterial und Verfahren für die Herstellung eines solchen |
DE10128004A1 (de) | 2001-06-08 | 2002-12-19 | Vacuumschmelze Gmbh | Induktives Bauelement und Verfahren zu seiner Herstellung |
JP3861288B2 (ja) * | 2002-10-25 | 2006-12-20 | 株式会社デンソー | 軟磁性材料の製造方法 |
JP4452240B2 (ja) * | 2003-08-06 | 2010-04-21 | 日本科学冶金株式会社 | 軟磁性複合粉末及びその製造方法並び軟磁性成形体の製造方法 |
JP2008028162A (ja) * | 2006-07-21 | 2008-02-07 | Sumitomo Electric Ind Ltd | 軟磁性材料の製造方法、軟磁性材料、および圧粉磁心 |
DE102008048839A1 (de) * | 2008-09-25 | 2010-04-01 | Tridelta Weichferrite Gmbh | Weichmagnetischer Werkstoff |
JP5482097B2 (ja) * | 2009-10-26 | 2014-04-23 | Tdk株式会社 | 軟磁性材料、並びに、圧粉磁芯及びその製造方法 |
JP6071211B2 (ja) * | 2011-02-22 | 2017-02-01 | 三菱マテリアル株式会社 | 低磁歪高磁束密度複合軟磁性材とその製造方法 |
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2015
- 2015-04-09 DE DE102015105431.0A patent/DE102015105431A1/de not_active Withdrawn
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2016
- 2016-04-06 WO PCT/EP2016/057539 patent/WO2016162383A1/de unknown
- 2016-04-06 CN CN201680020737.7A patent/CN107396630B/zh active Active
- 2016-04-06 EP EP16715832.8A patent/EP3280558B1/de active Active
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CN107396630A (zh) | 2017-11-24 |
DE102015105431A1 (de) | 2016-10-13 |
EP3280558B1 (de) | 2020-11-04 |
CN107396630B (zh) | 2020-09-11 |
WO2016162383A1 (de) | 2016-10-13 |
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