EP3628423B1 - Alliage magnétique doux optimisé pour un moulage par injection de métal - Google Patents

Alliage magnétique doux optimisé pour un moulage par injection de métal Download PDF

Info

Publication number
EP3628423B1
EP3628423B1 EP19192779.7A EP19192779A EP3628423B1 EP 3628423 B1 EP3628423 B1 EP 3628423B1 EP 19192779 A EP19192779 A EP 19192779A EP 3628423 B1 EP3628423 B1 EP 3628423B1
Authority
EP
European Patent Office
Prior art keywords
iron
alloy
magnetic component
cases
cobalt
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.)
Active
Application number
EP19192779.7A
Other languages
German (de)
English (en)
Other versions
EP3628423A1 (fr
Inventor
John C. Difonzo
Abhijeet Misra
Charles J. Kuehmann
Daniel T. MCDONALD
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.)
Apple Inc
Original Assignee
Apple Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US16/273,761 external-priority patent/US11028468B2/en
Application filed by Apple Inc filed Critical Apple Inc
Publication of EP3628423A1 publication Critical patent/EP3628423A1/fr
Application granted granted Critical
Publication of EP3628423B1 publication Critical patent/EP3628423B1/fr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Images

Classifications

    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/10—Ferrous alloys, e.g. steel alloys containing cobalt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
    • B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
    • C22C33/0285—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with Cr, Co, or Ni having a minimum content higher than 5%
    • 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • 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 described embodiments relate generally to metal alloys. More particularly, the present embodiments relate to articles including metal alloys and methods of forming the same.
  • Soft magnetic materials are ferromagnetic materials, e.g. materials susceptible to magnetic fields, which do not retain their magnetism when an imposed magnetic field is removed. Soft magnetic materials can be useful in many applications, including electromagnetic cores, transformers, shunts, attraction plates, and other components of a magnetic circuit for use in electronic devices.
  • the permeability of a material is the ability of that material to allow or even amplify a magnetic field imposed on the material.
  • the saturation magnetization of a material is the capacity of that material to retain and respond to the magnetic flux of an imposed magnetic field. That is, the B sat is the density of magnetic flux in a material that corresponds to the saturated magnetization of the material from an applied external magnetic field.
  • Certain applications can require soft magnetic materials that have both a high saturation and a high permeability to achieve optimal performance levels. It may be desirable in some applications, however, to maximize only one of the saturation or permeability of the material to achieve optimal levels of performance. For example, in some applications, it may be desirable to provide a soft magnetic material that has a high saturation, regardless of the soft magnetic material's permeability.
  • the present description provides methods, components, such as for an electronic device, alloys, and other articles of manufacture that include or are formed from a soft magnetic alloy having a composition of about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron.
  • the alloy can have a composition of about 34 wt% to about 36 wt% cobalt and about 64 wt% to about 66 wt% iron.
  • the alloy can have a composition of about 34.5 wt% to about 35.5 wt% cobalt and about 64.5 wt% to about 65.5 wt% iron.
  • the alloy can have a composition of about 35 wt% cobalt and about 65 wt% iron. In some cases, the recited compositions exclude any impurities. It will be understood that the composition of the alloy cannot exceed 100 wt%.
  • Articles and components including the soft magnetic alloy described herein can be used in electronic devices, for example, as a magnetic shunt, attraction components, speaker components, or any other component in a magnetic circuit.
  • formulas for iron cobalt alloys may be written as FeCox, where X is the substantial weight percent of cobalt in the alloy, and 100-X is the substantial weight percent of iron in the alloy, excluding any impurities. That is, an iron cobalt alloy of the formula FeCox has approximately X wt% cobalt and approximately 100-X wt% iron, excluding any impurities.
  • impurities can refer to elements that may not serve a desired purpose or provide a desired effect to the material properties of the alloy, but which may be present in the alloy as a result of, for example, the processes used to form the alloy.
  • Such impurities can include one or more of nitrogen, oxygen, carbon, phosphorus, or sulphur, in addition to other elements.
  • the iron cobalt alloys described herein can include less than about 5 wt% impurities, less than about 3 wt% impurities, less than about 1 wt% impurities, or less than about 0.5 wt%, 0.25 wt%, 0.1 wt%, 0.01 wt%, or even fewer impurities.
  • Iron cobalt alloys are known to have amongst the highest magnetic saturation (B sat ) of any material. Accordingly, iron cobalt alloys are used as magnetic materials in a wide variety of applications, especially those applications where the B sat of a material is the primary determiner of performance. Traditionally, two formulas of iron cobalt alloys have been used commercially, FeCo 50 and FeCo 27 .
  • FeCo 50 has traditionally been used because it has a relatively high B sat for an iron cobalt alloy composition and also has a relatively high permeability. FeCo 50 can be difficult to process and form, however, because the temperature must be carefully controlled during processing in order to produce an article that includes the alloy in an ordered body-centered cubic phase. If the processing is not carefully controlled, the formed alloy can include a disordered phase which has a lower B sat and permeability than the alloy in an ordered phase. Articles formed from FeCo 50 are typically wrought, and the need to control the heat during wrought forming can be expensive and time consuming. Further, FeCo 50 can be brittle, adding to the alloy's processing difficulties.
  • iron cobalt alloys typically include other elements such as chromium or vanadium to make these alloys easier to work with and form, or to improve the mechanical properties of the alloy. Such additional elements, however, can lower the B sat and/or permeability of the alloy.
  • FeCo 27 has a similar B sat to FeCo 50 , it has a lower permeability. FeCo 27 , however, does not undergo an ordered-disordered phase transition, so the processing for an article including this alloy does not need to be as carefully controlled to achieve desired levels of B sat and permeability.
  • the comparatively relaxed processing requirements, along with a reduced level of cobalt as compared to FeCo 50 can result in reduced costs for articles formed from or including FeCo 27 .
  • the reduced amount of cobalt, relative to FeCo 50 can be desirable because it can result in a reduced need for cobalt extraction. Cobalt mining and extraction can be both environmentally and socially deleterious, and cobalt can be considered a conflict resource. As such, it can be desirable to limit the amount of cobalt included in an alloy or in an article of manufacture.
  • the iron cobalt alloy composition with the absolute highest B sat includes approximately 35 wt% cobalt and approximately 65 wt% iron.
  • This alloy composition includes less cobalt than FeCo 50 , resulting in reduced costs, and only slightly more cobalt than FeCo 27 .
  • care must still be taken to control the ordered-disordered phase transition of the alloy.
  • the costs associated with the additional processing needed to control the ordered-disordered phase transition of FeCo 35 have outweighed the benefits conveyed by the higher B sat of FeCo 35 .
  • an FeCo 35 alloy when processed or formed by a powder metallurgy process, such as a metal injection molding process, the heat during processing can be effectively controlled so that no or relatively little further processing can be required to control the ordered-disordered phase transition.
  • an article including FeCo 35 formed by a powder metallurgy process, such as a metal injection molding process can have a B sat higher than any other iron cobalt alloy composition and can be formed in a variety of shapes without the additional costs and compromises associated with wrought processing or the addition of magnetically detrimental elements, such as vanadium.
  • an iron cobalt alloy for example an alloy having a composition of about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron can have a Bsat of about 1.9 tesla (T) to about 2.58 T, about 2 T to about 2.4 T, about 2.1 T to about 2.4 T, or about 2.1 T to about 2.2 T.
  • an article or component including an iron cobalt alloy, as described herein can be used as a magnetic shunt.
  • a magnetic shunt can be a component in a magnetic circuit, such as in an electronic device.
  • the term magnetic shunt, or shunt is used to refer to any component or material that can adjust or direct magnetic flux, for example as part of a magnetic circuit.
  • a magnetic shunt can be any material, article, or component that has magnetic flux passing there through.
  • an article or component including an iron cobalt alloy, as described herein can interact with an electric circuit to produce an electromotive force (EMF).
  • EMF electromotive force
  • a component including an iron cobalt alloy can be a component in a speaker, such as a dynamic loudspeaker, and can have a magnetic field that opposes a magnetic field generated by a speaker coil to drive the speaker and produce a desired sound.
  • the components or articles including an iron cobalt alloy described herein can be formed by a powder metallurgy process, such as a metal injection molding process.
  • a metal injection molding process for forming an article including the alloy can include mixing a powder containing the alloy with a binder to form a moldable feedstock material, heating the moldable feedstock material, injecting the heated feedstock material into a mold, and cooling the molded material.
  • the process can further include heat treating the molded material after cooling, for example, in a reducing atmosphere, and/or treating the molded material, for example with a solvent, to remove binder therefrom.
  • An article or component including the alloy can include impurity elements, for example one or more of nitrogen, oxygen, carbon, phosphorus, or sulphur, in an amount of less than about 60 ppm.
  • an iron cobalt alloy, as described herein can include less than about 50 ppm, less than about 40 ppm, less than about 20 ppm, 10 ppm, 5 ppm, or even substantially 0 ppm of one or more of nitrogen, oxygen, carbon, phosphorus, or sulphur.
  • the article can have a density of greater than about 90%, such as between about 90% and about 98%, and the alloy can be in an ordered body-centered cubic phase.
  • the processes for forming an article or component including the alloy can result in unique microstructural characteristics that may not be achievable by other processing techniques, such as bulk forming processes.
  • the alloy can have an average grain size of from about 60 microns to 90 microns, and can have an average pore size of from about 2 microns to about 4 microns.
  • FIGS. 1-9 These and other embodiments are discussed below with reference to FIGS. 1-9 .
  • the detailed description given herein with respect to these Figures is for explanatory purposes only, and should not be construed as limiting.
  • FIG. 1 shows an example electronic device 100 in the form of wireless earbuds 101 and an associated case 102 that can include articles or components containing or formed from a soft magnetic alloy, as discussed herein.
  • the electronic device 100 can correspond to any electronic device, however, including a phone such as a smartphone, a portable media player, a media storage device, a portable digital assistant ("PDA"), a tablet computer, a computer, a mobile communication device, a GPS unit, a remote control device, and other computing devices.
  • PDA portable digital assistant
  • the electronic device 100 can be referred to as an electronic device, or a consumer device. Exemplary structures and components of the example electronic device 100 are described in detail below, with reference to FIG. 2 .
  • the case 102 of the electronic device 100 can include a permanent magnet 120 to retain the wireless earbuds 101 therein.
  • the wireless earbuds 101 can include a component 110 including a metal alloy formed from an iron cobalt alloy having a composition and formed by a process as described herein.
  • the component 110 can act as ferromagnetic shunt that can serve as a retention plate.
  • the iron cobalt alloy retention plate can be magnetically attracted to the permanent magnet 120 to pull the earbud 101 into the case 102 and retain it therein.
  • the magnet 120 can include an iron cobalt alloy, as described herein.
  • other components of the electronic device 100 can be formed from or include an iron cobalt alloy as described herein.
  • the speaker 130 of an earbud 101 can include a magnetic speaker component 131 formed from or including an iron cobalt alloy, as described herein.
  • the device 100 can also include internal components, such as processors, memory, circuit boards, batteries, sensors, and other similar components.
  • an article or component formed form or including an iron cobalt alloy as discussed herein can assume a variety of shapes.
  • the article can be substantially continuous or contiguous.
  • the article can include any desired apertures, cavities, protrusions, or other features for any given application of the article.
  • an article including an iron cobalt alloy formed by a process such as a metal injection molding process, as discussed herein, can assume any shape that can be achieved by such a process.
  • the materials and structures of the article 110, 131 formed from an iron cobalt alloy discussed with respect to FIGS. 1 and 2 can include any desired design or shape to serve any number of functions or to provide any number of specifically tailored properties.
  • the following figures and example alloys, processes, and articles illustrate a variety of different embodiments, including an iron cobalt alloy that can be combined in any number or manner of ways. Further details of the iron cobalt alloy are described below with reference to FIGS. 3 and 4 .
  • FIG. 3 is a chart depicting the intrinsic induction of annealed iron cobalt alloys as a function of alloy composition.
  • the intrinsic induction of a material is directly related to the B sat of the material.
  • the chart depicted in FIG. 3 effectively depicts the relative B sat of annealed iron cobalt alloys as a function of alloy composition.
  • the B sat of an iron cobalt alloy drops off in both directions as it departs from 35 wt% cobalt.
  • the B sat of an article can be central to achieving a desired level of performance, irrespective of other material or magnetic properties, such as permeability. Accordingly, to achieve an article having as high a B sat as possible, the iron cobalt alloy forming or included in the article can have a formula of FeCo 35 . In some cases, however, an iron cobalt alloy as described herein can have a composition of about 32 wt% cobalt to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron. In some cases, an iron cobalt alloy of such a composition can have the material properties as described herein and can have a B sat that is still sufficiently high for a variety of applications.
  • the material properties of iron cobalt alloys having about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron, formed by the processes described herein, can also include material properties that are unique to such iron cobalt alloys.
  • the following figures and example alloys, processes, and articles illustrate a variety of different embodiments including such iron cobalt alloys that can be combined in any number or manner of ways.
  • FIG. 4 shows a phase diagram of iron cobalt alloys.
  • iron -cobalt alloys having between about 30 wt% and about 70 wt% cobalt can undergo a phase transition from a disordered phase to an ordered body-centered cubic phase when cooled below about 800 °C to about 600 °C.
  • the transition from a disordered phase to an ordered phase may not have time to occur throughout all or part of the bulk of the alloy.
  • an iron cobalt alloy as described herein for example FeCo 35
  • FeCo 35 can be cooled from a temperature above the ordered-disordered phase boundary to a temperature below the phase boundary at a slow enough rate that the phase transition can occur through substantially all of an article formed from the alloy.
  • an article or component formed from or including an iron cobalt alloy, as described herein can be substantially entirely in an ordered body-centered cubic phase.
  • an article formed or molded by a powder metallurgy process such as by metal injection molding an iron cobalt alloy as described herein can be heat treated so that the article is substantially entirely in an ordered body-centered cubic phase.
  • the article can be heated to a temperature above the phase boundary and cooled so that the article is substantially entirely in an ordered body-centered cubic phase.
  • this heat treatment can be an additional process or step that the shaped article is subjected to.
  • treatment to produce an article that is substantially entirely in an ordered body-centered cubic phase can be achieved as part of an existing processes or forming step.
  • a metal injection molding process as described herein, can include a heating step to sinter or densify the molded article and/or remove or burn off binder from the molded article.
  • this sintering and/or binder removal step can involve temperatures and times that can result in an article that is substantially entirely in an ordered body-centered cubic phase.
  • an iron cobalt alloy as described herein can thus be free or substantially free of additional elements such as vanadium, chromium, copper, tungsten, nickel, manganese, and silicon.
  • an iron cobalt alloy according to the present disclosure can have less than about 0.02 wt%, less than about 0.01 wt%, or less of elements such as vanadium, chromium, copper, tungsten, nickel, manganese, and silicon.
  • the articles described herein do not include these additional elements in the iron cobalt alloy, the B sat of the alloy may be free of undesirable effects often caused by the presence of such additional elements.
  • the material properties of iron cobalt alloys having about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron, and formed by the processes described herein, can also include material properties that are unique to such iron cobalt alloys.
  • FIGS. 5-9 and associated example alloys, processes, and articles illustrate a variety of different embodiments including the present iron cobalt alloys that can be combined in any number or manner of ways.
  • FIG. 5 shows a flow diagram of a process 200 for forming an article or component including an iron cobalt alloy having about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron.
  • the iron cobalt alloy can have the formula FeCo 35 .
  • the process 200 for forming an article or component can include heating a material including an iron cobalt alloy having about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron, at block 210; molding the material, at block 220, into a desired shape; and cooling the molded material, at block 230.
  • the process can also include additional steps or treatment stages as discussed herein.
  • a material including an iron cobalt alloy having about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron is heated.
  • the material can be a powder having a composition of about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron.
  • about 10% of the particles of the powder can have a maximum diameter or major dimension less than about 4 microns.
  • about 50% of the particles of the powder can have a maximum diameter or major dimension less than about 9 microns.
  • about 80% of the particles of the powder can have a maximum diameter or major dimension less than about 13 microns.
  • about 90% of the particles of the powder can have a maximum diameter or major dimension less than about 16 microns. In some cases, about 99.95% of the particles of the powder can have a maximum diameter or major dimension less than about 23 microns. In some cases, the powder can have a tapped density of between about 3 and about 6 grams/cm 3 , between about 4 and about 5 grams/cm 3 , between about 4.5 and about 5 grams/cm 3 , or between about 4.8 and about 5 grams/cm 3 .
  • the powder can have a bulk density of between about 3 and about 6 grams/cm 3 , between about 4 and about 5 grams/cm 3 , between about 4 and about 4.5 grams/cm 3 , orbetween about 4.2 and about 4.4 grams/cm 3 .
  • the material can be part of a feedstock.
  • the material can be combined with a binder material.
  • the binder material can be, for example, an organic or polymeric material such as wax or polypropylene.
  • the binder can serve to hold or bind particles of the powder, including the iron cobalt alloy together as part of a feedstock or slurry.
  • a feedstock can include a powder of the iron cobalt alloy and a binder.
  • the feedstock or material including the iron cobalt alloy can be heated to a temperature high enough to allow the feedstock to be formed in a mold.
  • the feedstock can be heated to a temperature high enough that the feedstock is in a substantially liquid state.
  • heating at block 210 results in the feedstock having rheological properties that are conducive to or enable forming in a mold.
  • the heated material or feedstock can then be molded into a desired shape, at block 220.
  • Any kind, form, or shape of mold can be used to form the feedstock into a molded material having the desired shape, for example, as discussed herein.
  • the molding stage can include any kind of powder metallurgy process.
  • the molding stage can include a powder forging process, a hot isostatic pressing process, a metal injection molding process, an electric current assisted sintering process, and additive manufacturing process, such as 3D printing, and combinations thereof.
  • the process of block 220 can include a metal injection molding process.
  • the process of block 220 can include injecting the heated material including the iron cobalt alloy, for example as part of a feedstock, into a mold having an inverse shape of the article or component desired to be formed.
  • the mold and/or article can assume any shape or combination of shapes.
  • the metal injection molding process can include or utilize plastic injection molding machines or apparatuses.
  • the metal injection molding process can include or utilize machines or apparatuses designed specifically for metal injection molding.
  • the molded material can be cooled.
  • the molded material can be cooled to, for example, ambient or room temperature.
  • the molded material can be cooled to a temperature low enough that the molded material can substantially retain a desired shape.
  • the cooling can produce a molded body, also referred to as a 'green' body, that can have a substantially similar shape to the desired shape of the article being formed by the exemplary process 200.
  • the cooled molded material can have a substantially similar shape to a final formed article, in some embodiments, for example where the material is part of a feedstock, the cooled molded material can include binder material therein.
  • the cooled molded material can include discrete alloy particles and can have a density substantially lower than a final density of a formed article, as described herein.
  • the molded or green body can be removed from the mold and in some embodiments, the process 200 can further include additional steps or stages for treating or processing the cooled molded material to form an article including an iron cobalt alloy, as described herein.
  • the cooled molded material can be subjected to a binder removal treatment or process.
  • a binder removal process can include exposing the molded body to a solvent that can dissolve or otherwise remove binder from the molded body, for example, by submerging the molded body in a liquid solvent.
  • a binder removal process can include exposing the molded body to a solvent, heating the molded body to a temperature above a binder decomposition or evaporation temperature, performing catalytic processes, and combinations thereof.
  • the molded body can, in some cases, be subjected to a sintering or densifying process.
  • a sintering or densifying process can be carried out after an optional binder removal step.
  • a sintering or densifying process can also serve as a binder removal step.
  • the molded material can be subjected to a sintering or densifying process prior to being removed from the mold or even prior to being cooled.
  • a sintering or densifying process can include heating the molded body to a temperature below the melting point of the iron cobalt alloy, but high enough to fuse alloy particles together, densify the molded body, and produce a substantially unitary or continuous article or alloy.
  • the sintering process can be a liquid phase sintering process where the body is heated to a temperature high enough that some partial melting of the alloy can occur.
  • a sintering or densification process can include heating the molded body to one or more temperatures at a desired rate and over a desired amount of time, in accordance with a desired temperature profile. For example, the molded body can be heated to a first temperature at a first rate and held at that temperature for a first duration, and then heated to a second, different temperature at a second rate and held at the second temperature for a second duration. Any number of temperatures and heating stages can be included in the sintering or densification process. Further, in some embodiments, a sintering or densification process can be carried out at elevated pressures, for example above atmospheric pressure. In some embodiments, a sintering or densification process can include an isostatic pressing process, such as a hot isostatic pressing process.
  • the process 200 can also include a heat treatment stage or step that can result in an article that is substantially entirely in an ordered body-centered cubic phase.
  • a treatment process can include heating the molded body to a temperature above an ordered-disordered phase boundary and cooling the molded body at a rate sufficiently slow to produce an article that is substantially entirely in an ordered body-centered cubic phase.
  • this heat treatment stage can be achieved by one or more other stages of the process 200. That is, in some cases, a heat treatment step or stage may not be a separate processing step, but can instead occur during one or more of the processing stages described herein.
  • the treatment to produce an article that is substantially entirely in an ordered body-centered cubic phase can include the binder removal treatment, the sintering or densification treatment, the cooling stage 230, or combinations thereof.
  • the temperatures and times involved in the processing steps described herein can be sufficient to achieve a desired treatment, for example, sintering of the molded body, while also resulting in an article that is substantially entirely in an ordered body-centered cubic phase.
  • a heat treatment process such as a sintering process, can include heating the molded body to a maximum temperature of about 1000 °C, or about 1100 °C, 1200 °C, 1300 °C, 1400 °C, or greater, In some cases, the heat treatment process can include raising the molded body to a temperature, such as about 1400 °C, at a constant or variable rate. In some cases, the heat treatment can include holding the molded body at one or more substantially constant temperatures for a duration during the ramp up to a maximum temperature, such as about 1400 °C.
  • the molded body can be held at one or more temperature for a duration of about 1 minute, about 5 minutes, about 10 minutes, about 15 minutes, about 20 minutes, about 30 minutes, about 45 minutes, about an hour, or about 2 hours or more during the ramp up to a maximum temperature.
  • heat treatment can include holding the molded body at a temperature, such as about 1400 °C, for a duration.
  • the duration can be up to about 1 hour, up to about 2 hours, up to about 3 hours, up to about 5 hours, or more.
  • the heated molded body can be cooled, for example back to an ambient environmental temperature, such as room temperature, at a constant or variable rate including holding one or more temperatures substantially constant for duration, for example, in a similar manner to the ramping profile.
  • any of the above described blocks, such as blocks 210, 220, and 230 of process 200, as well as any further treatments, such as a binder removal or sintering treatment can be carried out in an inert atmosphere, such as an argon or a nitrogen atmosphere.
  • any of the above described blocks, such as blocks 210, 220, and 230 of process 200, as well as any further treatments, such as a binder removal or sintering treatment can be carried out in reduced pressure environment, such as a vacuum.
  • any of the above described blocks, such as blocks 210, 220, and 230 of process 200, as well as any further treatments, such as a binder removal or sintering treatment can be carried out in a reducing atmosphere.
  • the material properties of iron cobalt alloys having about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron, formed by the processes described herein, can also include material properties that are unique to such iron cobalt alloys.
  • the following figures and example alloys, processes, and articles illustrate a variety of different embodiments including such iron cobalt alloys that can be combined in any number or manner of ways.
  • FIG. 6 shows a flow diagram of a process 300 for forming a metal alloy having a composition about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron.
  • the iron cobalt alloy can have the formula FeCo 35 .
  • the process 300 can include heating a feedstock including a material having about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron, at block 310; injecting the feedstock into a mold, at block 320; cooling the molded material, at block 330; and sintering the molded material, at block 340.
  • a feedstock including a material having about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron is heated.
  • the feedstock and heating process can be substantially similar to those discussed with respect to block 210 of FIG. 5 .
  • the material included in the feedstock can be a powder having a composition of about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron.
  • the material can be a metal alloy powder having to formula FeCo 35 .
  • the feedstock can also include an organic or polymeric binder material.
  • the feedstock can be a slurry including a binder and an iron cobalt alloy powder having a composition of about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron.
  • the feedstock including the material can be heated to a temperature such that the slurry has rheological properties or characteristics that can allow or enable the injection process of block 320.
  • the heated feedstock including the material having about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron is injected into a mold.
  • the mold can have any desired shape or form, and in some cases, can have a shape substantially the inverse of or corresponding to a shape of the final formed article.
  • injecting the feedstock can include metal injection molding.
  • the feedstock is a slurry including a binder and an iron cobalt alloy powder
  • the heated feedstock can be injected into a mold under pressure.
  • the process can include or utilize plastic injection molding machines or apparatuses.
  • the metal injection molding process can include or utilize machines or apparatuses designed specifically for metal injection molding.
  • the injection molded material can be cooled at block 330.
  • Block 330 can be carried out in a substantially similar manner to block 230 of FIG. 5 , as discussed herein.
  • the injection molded material can be cooled to, for example, ambient or room temperature. In some cases, the molded material can be cooled to a temperature low enough that the molded material can substantially retain a desired shape.
  • the cooling can produce a molded body, also referred to as a 'green' body, that has a substantially similar shape to the desired shape of the article being formed by process 300.
  • the cooled molded material can have a substantially similar shape to a final formed article, in some embodiments, the cooled molded material can include binder material therein. Further, in some embodiments, the cooled molded material can include discrete alloy particles and can have a density substantially lower than a final density of a formed article, as described herein.
  • the molded body or material can be sintered or otherwise densified at block 340.
  • the molded material can be removed from the mold prior to the sintering or densifying.
  • sintering or densifying can include heating the molded material to one or more temperatures to sinter or fuse particles of the material, for example, to a form a substantially unitary or continuous body or alloy.
  • sintering can include heating the molded material to a temperature below the melting point of the iron cobalt alloy.
  • sintering can include liquid phase sintering where the body can be heated to a temperature at or near the melting point of the iron cobalt alloy so that partial melting and reflowing, for example via capillary action, can occur.
  • a sintering or densification process can include heating the molded body to one or more temperatures at a desired rate and over a desired amount of time, in accordance with a desired temperature profile. Further, in some embodiments, a sintering or densification process can be carried out at elevated pressures, for example, above atmospheric pressure. In some embodiments, a sintering or densification process can include an isostatic pressing process, such as a hot isostatic pressing process.
  • the sintering or densification of block 330 can be carried out in such a manner, for example, by heating to one or more desired temperatures, cooling the sintered alloy, and controlling the heating and/or cooling rates of the alloy, that the resultant sintered alloy is substantially in an ordered body-centered cubic phase.
  • sintering at block 340 can include heating the molded body to a temperature above an ordered-disordered phase boundary and cooling the molded body at a rate sufficiently slow to produce an article that is substantially in an ordered body-centered cubic phase.
  • the sintering can be carried out in an inert atmosphere, such as an argon or a nitrogen atmosphere.
  • any of the above described blocks, such as blocks 310, 320, 330, 340 of process 300, as well as any further treatments, such as a binder removal or sintering treatment can be carried out in a reduced pressure environment, such as a vacuum.
  • any of the above described blocks, such as blocks 310, 320, 330, and 340 of process 300, as well as any further treatments, such as a binder removal or sintering treatment can be carried out in a reducing atmosphere.
  • the process 300 can further include additional steps or stages for treating or processing the molded body or alloy, for example, to form an article including an iron cobalt alloy, as described herein.
  • the molded body or alloy can be subjected to a binder removal treatment or process.
  • a binder removal process can include exposing the molded body to a solvent that can dissolve or otherwise remove binder from the molded body, for example, by submerging the molded body in a liquid solvent.
  • a binder removal process can include exposing the molded body to a solvent, heating the molded body to a temperature above a binder decomposition or evaporation temperature, performing catalytic processes, and combinations thereof.
  • any of the above described blocks, such as blocks 310, 320, 330, and 340 of process 300, as well as any further treatments, such as a binder removal or sintering treatment, can be carried out in an inert atmosphere, such as an argon or nitrogen atmosphere.
  • any of the above described blocks of process 300, as well as any further treatments, such as a binder removal or sintering treatment can be carried out in reduced pressure environment, such as a vacuum.
  • the material properties of iron cobalt alloys having about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron, and formed by the processes described herein, can also include material properties that are unique to such iron cobalt alloys.
  • the following figures and example alloys, processes, and articles illustrate a variety of different embodiments including such iron cobalt alloys that can be combined in any number or manner of ways.
  • FIG. 7 shows a schematic view of a system 400 for forming an article including an iron cobalt alloy.
  • the system 400 can be used to carry out the processes for forming an article, component, or alloy including about 34 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron, for example, as described with respect to FIGS. 5 and 6 .
  • the system 400 can include a mold 410 including a cavity 411 for receiving a feedstock 401 including an iron cobalt alloy, as described herein.
  • An injection apparatus 420 is configured to inject the feedstock 401 into the mold 410, and a furnace 430 can be used to, for example, sinter, heat treat, and/or remove binder, if any is present, from the molded material.
  • the mold 410 can include a cavity 411 having any desired shape or design.
  • the cavity 411 of the mold 410 can include a shape corresponding substantially to an inverse shape of an article including the iron cobalt alloy.
  • the cavity 411 can include multiple portions or regions in fluid communication with one another, each portion corresponding substantially to an inverse shape of an article so that multiple articles can be molded at the same time.
  • the mold 410 can include an inlet 412 for receiving feedstock 401 into the cavity 411.
  • the feedstock 401 that can be provided into the mold 410 can include an iron cobalt alloy having about 32 wt% to about 38 wt% cobalt and about 62 wt% to about 68 wt% iron, as discussed herein.
  • the feedstock can include the iron cobalt alloy in powder form and can additionally include a binder, such as an organic or polymeric binder.
  • the feedstock 401 can be a slurry including a binder and an iron cobalt alloy powder having a composition of between about 32 wt% and about 38 wt% cobalt and about 62 wt% to about 68 wt% iron.
  • the feedstock 401 can be provided into the cavity 411 of the mold 410 via the inlet 412 by an injection apparatus 420.
  • the injection apparatus 420 and the mold 410 can be included as a single device or apparatus.
  • the injection apparatus 420 can be a plastic injection molding apparatus. In some cases, however, the injection apparatus 420 can be specifically designed or intended to be used in a metal injection molding process, for example, as discussed with respect to FIG. 6 .
  • the injection apparatus 420 can include a hopper 421 for receiving the feedstock 401 to be injected into the mold 410.
  • the hopper 421 can include any shape or form, and in some cases, can include a cavity or space for storing the feedstock 401.
  • the hopper 421 can be an inlet of the injection apparatus 420 and can receive feedstock 401 in any manner, for example, as fed to the hopper 421 by a hose or other device.
  • the feedstock 401 can be moved from the hopper 421, through the body of the apparatus 420, to a nozzle 422, where it can be provided into the mold 410, as discussed herein.
  • the nozzle 422 can be sized to correspond to the inlet 412 of the mold 410 and can positioned in fluid communication with and substantially adjacent thereto.
  • the feedstock 401 can be moved from the hopper 421 to the nozzle 422 by, for example, a reciprocating screw, pump, plunger, or the like, of the injection apparatus 420.
  • the feedstock 401 can be provided to the injection apparatus 420 in a substantially solid form and can be heated by the apparatus 420 to a substantially liquid state prior to being injected into the mold 410.
  • the feedstock 401 can be heated to a temperature such that the material 401 has rheological properties or characteristics that can allow or enable the feedstock 401 to conform to the shape of the cavity 411.
  • the injection apparatus 420 can include a heater 423 to achieve the above-described heating of the feedstock 401.
  • the heater 423 can heat the feedstock 401 as it passes from the hopper 421 to the nozzle 422, and can, for example, be positioned adjacent to the screw, pump, plunger, or other system, that is used to move the feedstock 401 through the injection apparatus 420. In some other cases, however, the feedstock 401 can be provided in a heated and/or liquid state to the injection apparatus 420, and a heater may maintain a temperature of the feedstock 401, or may not be included in the injection apparatus 420 at all.
  • the system 400 can further include a furnace 430.
  • the furnace 430 can receive the molded material 401' and can heat the molded material 401' to carry out a sintering, densification, binder removal, and/or heat treatment process for example as discussed with respect to FIGS. 5 and 6 . Heating the molded material or body 401' in the furnace 430 can thus produce a formed article including the iron cobalt alloy described herein.
  • the molded material 401' can be removed from the mold 410 to produce a green body, and this green body or bodies can be received by the furnace 430 for heating therein. In some other cases, however, the molded material 401 ' can remain in the mold 410 while it is provided to the furnace 430 for heating.
  • the material properties of iron cobalt alloys having between about 32 wt% and about 38 wt% cobalt and about 62 wt% to about 68 wt% iron, and formed by the processes described herein, can include material properties that are unique to such iron cobalt alloys.
  • an article including an iron cobalt alloy having a composition of between about 32 wt% and about 38 wt% cobalt and about 62 wt% to about 68 wt% iron and formed according to the processes discussed herein, such as a metal injection molding process can include an average pore or void size of from about 1 micron to about 5 microns, from about 2 microns to about 4 microns, from about 2 microns to about 3.5 microns, from about 2 to about 2.5 microns, or from about 3 to about 3.5 microns.
  • the iron cobalt alloy of such an article can have an average grain size of from about 50 microns to about 100 microns, from about 60 microns to about 90 microns, from about 70 microns to about 80 microns, or from about 74 microns to about 77 microns, In some cases, an iron cobalt alloy can have an average grain size of about 75 microns. In some cases, however, an iron cobalt alloy can have an average grain size of greater than about 200 microns, greater than about 250 microns, 300 microns, 350 microns or greater.
  • the density of an article including an iron cobalt alloy having a composition of between about 32 wt% and about 38 wt% cobalt and about 62 wt% to about 68 wt% iron and formed according to the processes discussed herein, such as a metal injection molding process can exhibit a density between about 88% and about 99%, between about 90% and about 98%, between about 92% and about 97%, between about 93% and about 97%, between about 94% and about 97%, or between about 95% and about 97%.
  • such an article can include less than about 5 wt% impurities, less than about 3 wt% impurities, less than about 1 wt% impurities, or less than about 0.5 wt%, 0.25 wt%, 0.1 wt%, 0.01 wt%, or even fewer impurities.
  • impurity elements can include nitrogen, oxygen, carbon, phosphorus, hydrogen, sulphur, and combinations thereof.
  • such an article can be substantially free of additive elements such as vanadium, chromium, copper, tungsten, nickel, manganese, and silicon.
  • FIG. 8 shows a series of optical micrographs of iron cobalt alloys, including two samples of iron cobalt alloy having a composition of approximately 50 wt% iron and of approximately 50 wt% cobalt (FeCo 50 ), and two samples of iron cobalt alloy having a composition of approximately 35 wt% cobalt and approximately 65 wt% iron (FeCoss).
  • FeCo 50 samples One of the FeCo 50 samples was formed or shaped by a wrought process, while the second FeCo 50 sample was formed by a metal injection molding process, for example, as described herein. Both of the FeCo 35 samples were formed by a metal injection molding process, as described herein.
  • the FeCo 50 sample produced using the wrought process has an average grain size of about 54.4 microns, which is lower than the iron cobalt alloy samples prepared using a metal injection molding process, and significantly lower than the other FeCo 50 sample prepared using a metal injection molding process.
  • an iron cobalt alloy formed from a metal injection molding process can have an average grain size that is larger than the average grain size of an iron cobalt alloy having the same composition, produced by a wrought process.
  • the FeCo 35 samples have average grain sizes of about 76.3 microns and 75.7 microns, respectively. These average grain sizes are smaller than the 107.1 micron average grain size of the FeCo 50 sample produced by metal injection molding.
  • an iron cobalt alloy having between about 32 wt% and about 38 wt% cobalt and about 62 wt% to about 68 wt% iron can have a smaller average grain size than an iron cobalt alloy prepared by a similar processing method, such as metal injection molding. Additionally, the iron cobalt alloy having between about 32 wt% and about 38 wt% cobalt and about 62 wt% to about 68 wt% iron, can have a grain size more akin to a wrought FeCo 50 alloy.
  • FIG. 9 shows a series of scanning electron micrographs of the same iron cobalt alloy samples analyzed in FIG. 8 , in the same respective order. That is, two FeCo 50 samples, one formed by a wrought process, the other formed by a metal injection molding process, and two FeCo 35 samples, each formed by metal injection molding processes. A survey of the pores or voids of each sample was taken from representative areas of the samples and the average pore size of the samples was calculated. The average pore or void diameter of the wrought FeCo 50 sample was found to be about 1.5 microns. The average pore diameter of the second FeCo 50 sample formed by a metal injection molding process was found to be approximately 3.3 microns. Accordingly, in some cases, an iron cobalt alloy formed by a metal injection molding process can have an average pore diameter or size that is much greater than an alloy of a similar composition that is formed by a wrought process.
  • the FeCo 35 samples were found to have an average pore diameter of 2.3 microns and 3.3 microns, respectively, while the metal injection molded FeCo 50 sample was found to have an average pore diameter of about 3.3 microns.
  • the porosity of each sample was also measured. That is, the area fraction of each sample that was occupied by pores or voids in the representative micrograph.
  • the FeCo 50 sample had a porosity of 3%. While this porosity was slightly lower than one of the FeCo 35 samples (found to be 3.3%), the average pore diameter of the FeCo 50 sample was 3.3 microns compared to 2.3 microns for the FeCo 35 sample.
  • an iron cobalt alloy having between about 32 wt% and about 38 wt% cobalt and about 62 wt% to about 68 wt% iron can have a lower porosity (and higher density) than an iron cobalt alloy prepared by a similar processing method, such as metal injection molding, but having a higher weight percentage of cobalt, for example a FeCo 50 alloy.
  • Table 1 shows a variety of experimentally measured properties of iron cobalt alloy samples prepared by a metal injection molding process, for example, as described herein. As can be seen in the table, two FeCo 50 samples and two FeCo 35 samples were prepared. The samples were prepared using substantially similar processes and treatment regimes. TABLE 1 Sample Composition % Density B sat (T) B r (T) ⁇ Max H c (A/m) FeCo 50 94.8 2.286 1.683 9495.8 88.8 FeCo 50 93.4 2.178 1.104 6823.6 75.6 FeCo 35 95.7 2.176 0.508 1488.0 156.2 FeCo 35 94.9 2.037 0.853 2000.6 155.7
  • the B sat is the saturation of the sample, as discussed herein, while the Br is the maximum magnetic flux density that the sample can produce.
  • the ⁇ Max is the maximum permeability of the sample, as discussed herein.
  • the H c of each sample is the coercive field strength, or the force necessary to demagnetize the sample. As can be seen in Table 1, the FeCo 35 samples were found to have higher densities than the FeCo 50 samples, which was consistent with the results as shown in FIG. 9 above.
  • an iron cobalt alloy having between about 32 wt% and about 38 wt% cobalt and about 62 wt% to about 68 wt% iron can have a lower porosity (and higher density) than an iron cobalt alloy prepared by a similar processing method, such as metal injection molding, but having a higher weight percentage of cobalt, for example a FeCo 50 alloy.
  • the B sat of the FeCo 50 and FeCo 35 samples were found to be substantially similar.
  • the B sat of an iron cobalt alloy can be the determinative material property for achieving a desired level of performance, irrespective of other material or magnetic properties, such as ⁇ Max .
  • the FeCo35 samples may have different values for B r , ⁇ Max , and H c , Table 1 illustrates that FeCo 50 and FeCo 35 samples can perform substantially similarly in some applications.
  • an article or component including an iron cobalt alloy having between 32 wt% and 38 wt% cobalt and about 62 wt% to about 68 wt% iron can include any design or shape and can be formed by any of the processes described herein, including a metal injection molding process.
  • an article including an iron cobalt alloy having between 32 wt% and 38 wt% cobalt and about 62 wt% to about 68 wt% iron and formed according to the processes described herein can have any of the microstructural characteristics discussed herein in any combination, including an average pore size of between about 2 and about 4 microns, an average grain size of between about 60 and about 90 microns, and/or a density of between about 90% and about 98%.

Landscapes

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

Claims (13)

  1. Un composant magnétique pour un dispositif électronique, comprenant un alliage métallique dans une phase cubique à corps centré ordonnée, l'alliage métallique étant constitué de 32 à 38 % en poids de cobalt, éventuellement d'un ou plusieurs parmi l'oxygène, le phosphore et le soufre, et le reste de fer, le composant magnétique ayant une porosité entre 2 % et 10 % et une dimension moyenne de pore de 2 microns à 5 microns.
  2. Le composant magnétique de la revendication 1, dans lequel l'alliage métallique comprend 34 % en poids à 36 % en poids de cobalt, et 64 % en poids à 66 % en poids de fer.
  3. Le composant magnétique de la revendication 1, dans lequel l'alliage métallique comprend 35 % en poids de cobalt et 65 % en poids de fer.
  4. Le composant magnétique de l'une des revendications 1 à 3, dans lequel l'alliage métallique présente une dimension granulométrique moyenne de 60 microns à 100 microns.
  5. Le composant magnétique de l'une des revendications 1 à 4, dans lequel l'alliage métallique a une densité de 90 % à 98 %.
  6. Le composant magnétique de l'une des revendications 1 à 5, dans lequel l'alliage métallique a une densité de 95 % à 97 %.
  7. Le composant magnétique de l'une des revendications 1 à 6, dans lequel l'alliage métallique comprend moins de 60 parties par million (ppm) de chacun d'entre l'oxygène, le phosphore et le soufre.
  8. Le composant magnétique de l'une des revendications 1 à 7, dans lequel le composant magnétique est un shunt magnétique.
  9. Le composant magnétique de l'une des revendications 1 à 7, dans lequel le composant magnétique est un composant de retenue magnétique.
  10. Le composant magnétique de l'une des revendications 1 à 7, dans lequel le composant magnétique est configuré pour interagir avec un circuit électrique pour produire une force électromotrice.
  11. Le composant magnétique de l'une des revendications 1 à 10, dans lequel l'alliage métallique présente une magnétisation à la saturation (Bsat) comprise entre 2 tesla (T) et 2,3 T.
  12. Le composant magnétique de l'une des revendications 1 à 11, dans lequel le composant magnétique est formé par un processus de moulage par injection de métal.
  13. Le composant magnétique de l'une des revendications 1 à 12, dans lequel le composant magnétique est formé à partir d'une poudre, avec 90 % des particules de la poudre qui ont un diamètre maximal inférieur à 16 microns.
EP19192779.7A 2018-09-28 2019-08-21 Alliage magnétique doux optimisé pour un moulage par injection de métal Active EP3628423B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201862738507P 2018-09-28 2018-09-28
US16/273,761 US11028468B2 (en) 2018-09-28 2019-02-12 Soft magnetic alloy optimized for metal injection molding

Publications (2)

Publication Number Publication Date
EP3628423A1 EP3628423A1 (fr) 2020-04-01
EP3628423B1 true EP3628423B1 (fr) 2023-06-28

Family

ID=86498055

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19192779.7A Active EP3628423B1 (fr) 2018-09-28 2019-08-21 Alliage magnétique doux optimisé pour un moulage par injection de métal

Country Status (2)

Country Link
EP (1) EP3628423B1 (fr)
CN (1) CN116469636A (fr)

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1928169A (en) * 1930-07-19 1933-09-26 Columbia Graphophone Co Ltd Electric sound recorder
US2603678A (en) * 1946-10-01 1952-07-15 Helmer Transmission Corp Magnetic torque transmission
RO125436B1 (ro) * 2008-11-06 2013-10-30 Institutul Naţional De Cercetare-Dezvoltare Pentru Inginerie Electrică Icpe-Ca PROCEDEU DE OBȚINERE A UNUI ALIAJ MAGNETIC TIP Fe-50%Co

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
HAJIME ASANO ET AL: "Order-Disorder Transformation of Fe-Co Alloys in Fine Particles", TRANSACTIONS OF THE JAPAN INSTITUTE OF METALS., vol. 8, no. 3, 1 January 1967 (1967-01-01), JP, pages 180 - 184, XP055771761, ISSN: 0021-4434, DOI: 10.2320/matertrans1960.8.180 *

Also Published As

Publication number Publication date
CN116469636A (zh) 2023-07-21
EP3628423A1 (fr) 2020-04-01

Similar Documents

Publication Publication Date Title
US11028468B2 (en) Soft magnetic alloy optimized for metal injection molding
JP4873008B2 (ja) Ｒ−Ｆｅ−Ｂ系多孔質磁石およびその製造方法
KR101548274B1 (ko) 희토류 자석의 제조방법
JP4872887B2 (ja) Ｒ−Ｆｅ−Ｂ系永久磁石用多孔質材料およびその製造方法
CN107871582A (zh) R‑Fe‑B烧结磁体
CN107871581A (zh) 制备R‑Fe‑B烧结磁体的方法
CN105665715B (zh) 采用粉末冶金工艺制备的铁硅系软磁合金及方法
KR20120115490A (ko) 자석용 분말
JP2014145129A (ja) Ｒ−ｔ−ｂ−ｍ−ｃ系焼結磁石の製造方法、当該方法で製造された磁石、及びその製造装置
KR101087574B1 (ko) 반복 열처리를 통한 소결자석의 제조방법 및 그로부터 제조된 소결자석
CN106816253B (zh) 一种Mn-Ga合金磁硬化的方法
US5963771A (en) Method for fabricating intricate parts with good soft magnetic properties
EP3628423B1 (fr) Alliage magnétique doux optimisé pour un moulage par injection de métal
KR100524827B1 (ko) 희토류자석 제조의 고이방화 종축 성형방법 및 그 장치
EP2980815A1 (fr) Procédé de production d'aimant fritté
KR101837280B1 (ko) 희토류계 소결 자석의 제조방법
JPH09283358A (ja) Ｒ−Ｆｅ−Ｂ系焼結磁石の製造方法
CN106601406A (zh) 制备钕铁硼磁体的烧结方法
KR101567169B1 (ko) 스퍼터 분말을 이용하는 영구자석의 제조방법
CN113628822B (zh) SmFeN永磁体及其制备方法、电机
JP4302498B2 (ja) 等方性磁石の製造方法およびその磁石
JP6405881B2 (ja) 磁性ナノ粒子の製造方法
EP0156482A1 (fr) Alliages Sm2 CO17 utilisables comme aimants permanents
KR101451508B1 (ko) Nd-Fe-B계 희토류 소결 자석의 제조방법
KR101375986B1 (ko) 금속분말 사출성형법을 통한 Fe­Si 계 자성 코어 제조방법

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: REQUEST FOR EXAMINATION WAS MADE

17P Request for examination filed

Effective date: 20190821

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

AX Request for extension of the european patent

Extension state: BA ME

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: EXAMINATION IS IN PROGRESS

17Q First examination report despatched

Effective date: 20210209

GRAP Despatch of communication of intention to grant a patent

Free format text: ORIGINAL CODE: EPIDOSNIGR1

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: GRANT OF PATENT IS INTENDED

INTG Intention to grant announced

Effective date: 20230214

GRAS Grant fee paid

Free format text: ORIGINAL CODE: EPIDOSNIGR3

GRAA (expected) grant

Free format text: ORIGINAL CODE: 0009210

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE PATENT HAS BEEN GRANTED

AK Designated contracting states

Kind code of ref document: B1

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

REG Reference to a national code

Ref country code: CH

Ref legal event code: EP

REG Reference to a national code

Ref country code: AT

Ref legal event code: REF

Ref document number: 1582256

Country of ref document: AT

Kind code of ref document: T

Effective date: 20230715

REG Reference to a national code

Ref country code: IE

Ref legal event code: FG4D

REG Reference to a national code

Ref country code: DE

Ref legal event code: R096

Ref document number: 602019031593

Country of ref document: DE

REG Reference to a national code

Ref country code: LT

Ref legal event code: MG9D

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: SE

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

Ref country code: NO

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230928

REG Reference to a national code

Ref country code: NL

Ref legal event code: MP

Effective date: 20230628

REG Reference to a national code

Ref country code: AT

Ref legal event code: MK05

Ref document number: 1582256

Country of ref document: AT

Kind code of ref document: T

Effective date: 20230628

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: RS

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

Ref country code: NL

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

Ref country code: LV

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

Ref country code: LT

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

Ref country code: HR

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

Ref country code: GR

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230929

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: FI

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: SK

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: ES

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: IS

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20231028

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: SM

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

Ref country code: SK

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

Ref country code: RO

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

Ref country code: PT

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20231030

Ref country code: IS

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20231028

Ref country code: ES

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

Ref country code: EE

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

Ref country code: CZ

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

Ref country code: AT

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: PL

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: MC

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

REG Reference to a national code

Ref country code: CH

Ref legal event code: PL

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: MC

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

REG Reference to a national code

Ref country code: DE

Ref legal event code: R097

Ref document number: 602019031593

Country of ref document: DE

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: LU

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20230821

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: LU

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20230821

Ref country code: DK

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

Ref country code: CH

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20230831

PLBE No opposition filed within time limit

Free format text: ORIGINAL CODE: 0009261

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: NO OPPOSITION FILED WITHIN TIME LIMIT

REG Reference to a national code

Ref country code: BE

Ref legal event code: MM

Effective date: 20230831

REG Reference to a national code

Ref country code: IE

Ref legal event code: MM4A

GBPC Gb: european patent ceased through non-payment of renewal fee

Effective date: 20230928

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: IT

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

26N No opposition filed

Effective date: 20240402

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: IE

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20230821

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: GB

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20230928

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: IE

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20230821

Ref country code: GB

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20230928

Ref country code: FR

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20230828

Ref country code: SI

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20230628

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: BE

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20230831

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: DE

Payment date: 20240625

Year of fee payment: 6