EP4268995A1 - Method and installation for the production of a starting material for producing of rare earth magnet - Google Patents
Method and installation for the production of a starting material for producing of rare earth magnet Download PDFInfo
- Publication number
- EP4268995A1 EP4268995A1 EP23190243.8A EP23190243A EP4268995A1 EP 4268995 A1 EP4268995 A1 EP 4268995A1 EP 23190243 A EP23190243 A EP 23190243A EP 4268995 A1 EP4268995 A1 EP 4268995A1
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- EP
- European Patent Office
- Prior art keywords
- intermediate product
- rare earth
- starting material
- classifier
- powdery intermediate
- 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.)
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- 239000007858 starting material Substances 0.000 title claims abstract description 67
- 229910052761 rare earth metal Inorganic materials 0.000 title claims abstract description 66
- 150000002910 rare earth metals Chemical class 0.000 title claims abstract description 65
- 238000000034 method Methods 0.000 title claims abstract description 52
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 44
- 238000009434 installation Methods 0.000 title 1
- 239000002245 particle Substances 0.000 claims abstract description 84
- 239000013067 intermediate product Substances 0.000 claims abstract description 73
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 27
- 239000000956 alloy Substances 0.000 claims abstract description 27
- 230000003068 static effect Effects 0.000 claims abstract description 22
- 239000000463 material Substances 0.000 claims description 19
- 230000008569 process Effects 0.000 claims description 14
- 238000000926 separation method Methods 0.000 claims description 10
- 230000001681 protective effect Effects 0.000 claims description 9
- 230000005415 magnetization Effects 0.000 claims description 7
- 238000005245 sintering Methods 0.000 claims description 4
- 238000003825 pressing Methods 0.000 claims description 3
- 239000010419 fine particle Substances 0.000 description 31
- 239000011362 coarse particle Substances 0.000 description 27
- 239000000843 powder Substances 0.000 description 19
- 239000007789 gas Substances 0.000 description 17
- 230000005291 magnetic effect Effects 0.000 description 13
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 11
- 239000000203 mixture Substances 0.000 description 11
- 238000000227 grinding Methods 0.000 description 10
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 8
- 239000006247 magnetic powder Substances 0.000 description 8
- 239000006185 dispersion Substances 0.000 description 7
- 238000009826 distribution Methods 0.000 description 7
- 230000001105 regulatory effect Effects 0.000 description 6
- 239000000047 product Substances 0.000 description 5
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 238000007792 addition Methods 0.000 description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 4
- 239000012530 fluid Substances 0.000 description 4
- 229910052742 iron Inorganic materials 0.000 description 4
- 229910001172 neodymium magnet Inorganic materials 0.000 description 4
- 229910052757 nitrogen Inorganic materials 0.000 description 4
- 239000001301 oxygen Substances 0.000 description 4
- 229910052760 oxygen Inorganic materials 0.000 description 4
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 3
- 229910017052 cobalt Inorganic materials 0.000 description 3
- 239000010941 cobalt Substances 0.000 description 3
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 238000001878 scanning electron micrograph Methods 0.000 description 3
- 229910052692 Dysprosium Inorganic materials 0.000 description 2
- 229910052771 Terbium Inorganic materials 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 229910052796 boron Inorganic materials 0.000 description 2
- 238000011109 contamination Methods 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- KBQHZAAAGSGFKK-UHFFFAOYSA-N dysprosium atom Chemical compound [Dy] KBQHZAAAGSGFKK-UHFFFAOYSA-N 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000004992 fission Effects 0.000 description 2
- 238000011010 flushing procedure Methods 0.000 description 2
- 239000001307 helium Substances 0.000 description 2
- 229910052734 helium Inorganic materials 0.000 description 2
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 238000005192 partition Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 230000002269 spontaneous effect Effects 0.000 description 2
- GZCRRIHWUXGPOV-UHFFFAOYSA-N terbium atom Chemical compound [Tb] GZCRRIHWUXGPOV-UHFFFAOYSA-N 0.000 description 2
- 229910000521 B alloy Inorganic materials 0.000 description 1
- 229910000640 Fe alloy Inorganic materials 0.000 description 1
- 229910052688 Gadolinium Inorganic materials 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 229910000583 Nd alloy Inorganic materials 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- 229910052777 Praseodymium Inorganic materials 0.000 description 1
- 229910052772 Samarium Inorganic materials 0.000 description 1
- 230000003749 cleanliness Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 230000005347 demagnetization Effects 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000003302 ferromagnetic material Substances 0.000 description 1
- -1 ferrous metals Chemical class 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- UIWYJDYFSGRHKR-UHFFFAOYSA-N gadolinium atom Chemical compound [Gd] UIWYJDYFSGRHKR-UHFFFAOYSA-N 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000008240 homogeneous mixture Substances 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000001000 micrograph Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- KZUNJOHGWZRPMI-UHFFFAOYSA-N samarium atom Chemical compound [Sm] KZUNJOHGWZRPMI-UHFFFAOYSA-N 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
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- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07B—SEPARATING SOLIDS FROM SOLIDS BY SIEVING, SCREENING, SIFTING OR BY USING GAS CURRENTS; SEPARATING BY OTHER DRY METHODS APPLICABLE TO BULK MATERIAL, e.g. LOOSE ARTICLES FIT TO BE HANDLED LIKE BULK MATERIAL
- B07B13/00—Grading or sorting solid materials by dry methods, not otherwise provided for; Sorting articles otherwise than by indirectly controlled devices
- B07B13/003—Separation of articles by differences in their geometrical form or by difference in their physical properties, e.g. elasticity, compressibility, hardness
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07B—SEPARATING SOLIDS FROM SOLIDS BY SIEVING, SCREENING, SIFTING OR BY USING GAS CURRENTS; SEPARATING BY OTHER DRY METHODS APPLICABLE TO BULK MATERIAL, e.g. LOOSE ARTICLES FIT TO BE HANDLED LIKE BULK MATERIAL
- B07B13/00—Grading or sorting solid materials by dry methods, not otherwise provided for; Sorting articles otherwise than by indirectly controlled devices
- B07B13/04—Grading or sorting solid materials by dry methods, not otherwise provided for; Sorting articles otherwise than by indirectly controlled devices according to size
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/05—Metallic powder characterised by the size or surface area of the particles
- B22F1/052—Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
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- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/05—Mixtures of metal powder with non-metallic powder
- C22C1/051—Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/05—Mixtures of metal powder with non-metallic powder
- C22C1/058—Mixtures of metal powder with non-metallic powder by reaction sintering (i.e. gasless reaction starting from a mixture of solid metal compounds)
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C28/00—Alloys based on a metal not provided for in groups C22C5/00 - C22C27/00
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- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
- H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
- H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/0536—Alloys characterised by their composition containing rare earth metals sintered
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- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
- H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
- H01F1/0571—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes
- H01F1/0575—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together
- H01F1/0577—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together sintered
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- 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
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- 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
- H01F41/0253—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 for manufacturing permanent magnets
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- 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
- H01F41/0253—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 for manufacturing permanent magnets
- H01F41/0266—Moulding; Pressing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C15/00—Disintegrating by milling members in the form of rollers or balls co-operating with rings or discs
- B02C2015/002—Disintegrating by milling members in the form of rollers or balls co-operating with rings or discs combined with a classifier
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B04—CENTRIFUGAL APPARATUS OR MACHINES FOR CARRYING-OUT PHYSICAL OR CHEMICAL PROCESSES
- B04C—APPARATUS USING FREE VORTEX FLOW, e.g. CYCLONES
- B04C5/00—Apparatus in which the axial direction of the vortex is reversed
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- B22F9/00—Making metallic powder or suspensions thereof
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- B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
- B22F2009/041—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling by mechanical alloying, e.g. blending, milling
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- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
- B22F2009/044—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling by jet milling
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
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- 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
- C22C33/025—Making ferrous alloys by powder metallurgy having an intermetallic of the REM-Fe type which is not magnetic
Definitions
- the present invention relates to a method for producing a starting material for the production of rare earth magnets, a starting material and a system for producing a starting material for the production of rare earth magnets.
- a permanent magnet (also: permanent magnet) is a piece of a magnetizable material, for example iron, cobalt or nickel, which maintains its static magnetic field without the need for an electrical current flow (unlike electromagnets).
- a permanent magnet can be created by applying a magnetic field to a ferromagnetic material.
- rare earth magnets refers to a group of permanent magnets that essentially consist of ferrous metals (iron, cobalt, more rarely nickel) and rare earth metals (especially neodymium, samarium, praseodymium, dysprosium, terbium, gadolinium). They are characterized by the fact that they simultaneously have a high magnetic remanent flux density and a high magnetic coercive field strength and thus a high magnetic energy density.
- NiFeB neodymium, iron and boron
- Permanent magnets are made from crystalline powder.
- the magnetic powder is pressed into a mold in the presence of a strong magnetic field.
- the crystals align themselves with their preferred magnetization axis in the direction of the magnetic field.
- the compacts are then sintered. During sintering, the pulverized components of the powder are bonded together or compacted by heating, but none or at least not all of the starting materials are melted.
- the compacts are heated - often under increased pressure - in such a way that the temperatures remain below the melting temperature of the main components, so that the shape (shape) of the workpiece is retained.
- the magnetic powder is produced in particular by grinding the corresponding alloys or components, for example in fluid bed jet mills or similar grinding systems.
- fluid bed jet mills in particular, defined fine grinding takes place, with an exact upper grain limit, but with a not insignificant proportion of fine particles.
- the comminution energy is provided by gas jets.
- magnets made from the magnetic powders already known from the prior art have an opposing field stability or coercive field strength that requires improvement due to a high volume percentage of coarse content.
- the object of the invention is to further optimize the production of the starting mixture for the production of rare earth magnets in order to be able to produce improved rare earth magnets.
- the invention relates to a method for producing a powdery starting material intended for the production of rare earth magnets.
- a first step of the method involves comminution of an alloy comprising at least one rare earth metal, with a powdery intermediate product being formed from the alloy comprising at least one rare earth metal.
- a further step provides for carrying out at least one classification for the powdery intermediate product based on particle size and/or density, with a fraction of the powdery intermediate product formed by means of the at least one classification forming the starting material intended for the production of rare earth magnets.
- At least one dynamic classifier is provided for the method, which implements at least one dynamic classifier for the powdery intermediate product based on particle size and/or density and thereby separates the fraction from the powdery intermediate product which is the starting material intended for the production of rare earth magnets trains.
- the powdery intermediate product is fed to at least one static classifier.
- a static classifier can be removed from the at least one
- the portion separated from the powdery intermediate product is fed to the at least one dynamic classifier, which implements at least one dynamic classifier, which implements the at least one classification based on particle size and/or density for the portion separated from the powdery intermediate product by means of the at least one static classifier, and in this case the fraction from the portion separates, which forms the starting material intended for the production of rare earth magnets.
- the at least one dynamic classifier sifts the powdery intermediate product and also disperses it, from which the fraction is separated from the powdery intermediate product, which forms the starting material intended for the production of rare earth magnets.
- the at least one dynamic classifier separates coarse material from the powdery intermediate product and that, as part of a second classification based on particle size and/or density, the at least one dynamic classifier separates fine material separated from the powdery intermediate product.
- a portion of the powdery intermediate product separated from the fine and coarse material can provide the fraction that forms the starting material intended for the production of rare earth magnets.
- Embodiments have proven useful in which the first classification based on particle size and/or density and the second classification based on particle size and/or density are carried out via exactly one dynamic classifier. Furthermore, the alloy comprising at least one rare earth metal can be comminuted, preferably mechanically, in two separate steps, with the powdery intermediate product being formed from the comminutements in separate steps.
- the at least one dynamic classifier implements the at least one classification based on particle size and/or density for the powdery intermediate product under a protective gas atmosphere.
- the invention also relates to a starting material intended for the production of rare earth magnets, which is produced by a method according to one of previously described embodiments were produced.
- a proportion of particles > 8 ⁇ m is ⁇ 2 percent by volume, in particular in a range between 0.1 percent by volume and 1 percent by volume and / or a proportion of particles ⁇ 2 ⁇ m is ⁇ 2 percent by volume and in particular in a range between 0. 05 percent by volume and 2 percent by volume.
- the invention also relates to a system for producing a powdery starting material intended for the production of rare earth magnets.
- a system for producing a powdery starting material intended for the production of rare earth magnets can also be provided in the system described below and are therefore not mentioned redundantly.
- Features described below, which relate to various embodiments of the system according to the invention, can also be provided in the methods already described above.
- the system for producing a powdery starting material intended for the production of rare earth magnets comprises at least one comminution device, which is aimed at producing a powdery intermediate product by comminuting an alloy comprising at least one rare earth metal.
- the system further comprises at least one separating device, which can separate a fraction from the powdery intermediate product via at least one classification or sifting based on particle size and/or density, which forms the starting material intended for the production of rare earth magnets.
- the at least one separating device comprises at least one dynamic classifier, which can separate the fraction from the powdery intermediate product which forms the starting material intended for the production of rare earth magnets via a classification based on particle size and/or density.
- the at least one separating device comprises at least one static classifier, to which the powdery intermediate product can be fed.
- the at least one static classifier and the at least one dynamic classifier can be connected to one another in such a way that a portion separated from the supplied intermediate product by means of the at least one static classifier can be fed to the at least one dynamic classifier.
- the at least one dynamic safe can then, if necessary, separate the fraction from the supplied portion that forms the starting material intended for the production of rare earth magnets.
- the at least one dynamic classifier is designed to classify and disperse the supplied powdery intermediate product.
- the at least one comminution device comprises two successive comminution machines, each of which is designed for preferably mechanical comminution of the alloy comprising at least one rare earth metal and interacts with one another to produce the powdery intermediate product from the alloy comprising at least one rare earth metal.
- Embodiments in which the at least one dynamic filter can implement the classification based on particle size and/or density under a protective gas atmosphere have also proven successful.
- the starting material which can be produced within the framework of the previously described methods or by means of the previously described system, can essentially comprise particles of a target size range and hardly have any contamination with particles that are smaller than particles of a target size range. These are also referred to below as fine particles. Furthermore, the starting material produced within the framework of the previously described methods or by means of the previously described system can essentially hardly contain any contamination with particles that are larger than the particles of the target size range. These are also referred to below as coarse particles.
- a starting material which essentially only comprises particles with a size within the target size range in a substantially homogeneous mixture.
- the starting material which can be produced with the previously described methods or by means of the previously described system, embodiments have proven successful in which the starting material has particles in the target size range between 1 ⁇ m and 10 ⁇ m, in particular in a target size range between 2 ⁇ m and 8 ⁇ m.
- the starting material has particles in the target size range between 1 ⁇ m and 10 ⁇ m, in particular in a target size range between 2 ⁇ m and 8 ⁇ m.
- a starting material produced in the context of the preceding processes or by means of the system described above contains ⁇ 2 percent by volume of fine particles, in particular ⁇ 1 percent by volume. Furthermore, it can be provided that the starting material produced in the context of the preceding methods or by means of the system described above comprises ⁇ 2 percent by volume of coarse particles, in particular ⁇ 1 percent by volume.
- the starting material produced within the framework of the previously described method or by means of the previously described system essentially or predominantly contains particles in the target size range between 2 ⁇ m and 8 ⁇ m, with a proportion of particles whose size is above 8 ⁇ m being ⁇ 2 Percent by volume, in particular in a range between 0.1 percent by volume and 1 percent by volume and where a proportion of particles whose size is below 2 ⁇ m is ⁇ 2 percent by volume, in particular in a range between 0.05 percent by volume and 2 percent by volume.
- the at least one dynamic classifier already mentioned above and designed as part of the method according to the invention or the system according to the invention can comprise a classifying rotor.
- a speed of the classifying rotor can, if necessary, be controlled or regulated depending on a particle size distribution desired for the starting material to be produced.
- a control and/or regulating unit can be provided, which is connected to the at least one dynamic classifier.
- An algorithm can be stored on the control and/or regulating unit, via which the control and/or regulating unit independently regulates or controls a speed of the classifying rotor designed as a component of the at least one dynamic classifier, taking into account the respective particle size distribution desired for the starting material to be produced .
- the previously mentioned at least one static classifier which is provided in various embodiments of a method according to the invention or a system according to the invention, can optionally be designed by at least its cyclone classifier.
- the at least one cyclone classifier can possibly achieve a reduction in the proportion of fine particles.
- a separated via the at least one static classifier or the at least one cyclone classifier Powdery mixture, which is also referred to below as a powdery intermediate product, usually still contains up to 10 percent by volume of fine particles and / or up to 10 percent by volume of coarse particles even after the fine particles have been separated.
- the fine particles which are necessarily always present in such a powdery intermediate product, have a detrimental effect on the properties of the rare earth magnets made from them in several respects.
- the ground powder intermediate product which has possibly already been partially freed of fine particles via the at least one static classifier, is subjected to at least one further classifier process, implemented by at least one dynamic classifier.
- the powdery intermediate product is first dispersed and then a classification according to particle size and/or density is carried out for the dispersed powdery intermediate product.
- This dispersion and classification according to particle size and/or density can be carried out in exactly one dynamic classifier. Fine particles and/or coarse particles can then be separated from the powdery intermediate product via the at least one dynamic classifier or exactly one dynamic classifier.
- the dispersion of the intermediate product and the renewed separation of fine particles and/or coarse particles are carried out within a single device, in particular within a single dynamic classifier. Due to the high chemical reactivity of fine particles that may be present in high concentrations in the powdery intermediate product, the only dynamic classifier can If necessary, carry out dispersion and/or sifting under an inert gas atmosphere. Helium, argon, nitrogen, etc. are used as protective gases.
- the at least one rare earth metal formed as a component of the alloy can be formed, for example, by iron and/or boron.
- the alloy comprising at least one rare earth metal can be an NdFeB alloy.
- a starting material can be produced from this alloy comprising at least one rare earth metal, which essentially only comprises particles in the target size range between 1 ⁇ m to 10 ⁇ m, preferably between 2 ⁇ m to 8 ⁇ m.
- the starting mixture preferably comprises ⁇ 95 percent by volume, in particular ⁇ 98 percent by volume, of particles in the target size range, which target size range is set from 2 ⁇ m to 8 ⁇ m.
- the system already described can include a device for the coarse comminution of an alloy comprising at least one rare earth metal.
- a coarse powder fraction possibly formed from the alloy comprising at least one rare earth metal with the aid of the device for coarse comminution, can optionally be ground into a fine powder fraction in a device for fine comminution, which may be designed as part of the system, the fine powder fraction forming the powdery intermediate product.
- the device for fine comminution can be designed as a fluid bed jet mill.
- Figure 1 shows schematically process steps for producing a starting material AM for the production of rare earth magnets.
- R rare earth metal
- Fe iron
- B boron in the desired proportions.
- an NdFeB alloy is used to produce a so-called neodymium magnet used.
- an alloy must first be produced from the elements in the desired proportions.
- this alloy is subjected to coarse grinding. For example, in a mechanical grinding system or through embrittlement with hydrogen. In particular, particles with a size of up to a few mm are generated.
- the coarse particles gP are chemically stable and can also be easily oriented in magnetic fields, but they have negative effects on the opposing field stability of the magnet because these coarse particles gP remagnetize even in small magnetic opposing fields and thus worsen the opposing field stability (or the coercive field strength) of the entire magnet. For this reason, it is advantageous to further reduce the proportion of coarse particles gP in the starting mixture for the production of sintered permanent magnets.
- the particles fP of the fine fraction are chemically very reactive due to their fineness and react with the oxygen or even with the nitrogen from the environment even at the lowest oxygen concentrations. These fine particles fP can cause spontaneous powder fires during further processing of the powder.
- Another disadvantage of the finest particles fP is that these fine powder particles are very difficult to orient in the magnetic fields and pressing devices that are usually available (of the order of magnitude of approximately 10 - 20 kOe) and therefore worsen the remanence of the magnets made from them. For this reason, in a fourth or additional process step, fine particles, in particular particles with a diameter of ⁇ 1-2 ⁇ m, are removed from the fine powder fraction fPF.
- the mixture is passed through a cyclone that carries the fines through a suitable gas stream and thereby separates it from the mixture.
- a cyclone that carries the fines through a suitable gas stream and thereby separates it from the mixture.
- the intermediate product ZP is subjected to at least one further sifting process in order to produce unwanted fine particles fP or coarse particles gP or fine particles fP and coarse particles gP remove and thus further improve the homogeneity of the particles in the target size ZG, in particular in order to obtain a powder mixture as the starting material AM, which essentially only comprises particles with particle sizes in a target range between approximately 2 ⁇ m to 8 ⁇ m, since these particles are magnetically the represent the best powder fraction. All further steps, which in terms of timing follow the step according to number 4, are carried out with the help of a dynamic classifier 10 (cf. Figures 2 and 3 ) or a high-performance classifier.
- the particles with the target size ZG between 2 ⁇ m to 8 ⁇ m are chemically sufficiently stable so that they do not cause any additional oxidation in the normal manufacturing process. They can also be easily oriented using the usual magnetic fields. They therefore contribute significantly to achieving a high remanence of the magnets produced and are therefore desirable, necessary and useful.
- the powdery intermediate product ZP is dispersed in order to produce the most homogeneous distribution of the different particles of the intermediate product ZP.
- molecular and magnetic attractive forces between the particles are overcome and subsequent sifting and separation of fine particles and/or coarse particles following dispersion is possible.
- a dynamic classifier 10 is also used for this process step (cf. Figures 2 and 3 ) or high-performance classifiers are used.
- the dispersed powdery intermediate product ZP is sifted again and particles of the fine fraction and/or particles of the coarse fraction are removed. This creates an optimized separation of the finest and coarse particles to achieve the desired target particle size ZG.
- the fine proportion of particles whose size is less than 1 ⁇ m is reduced to a proportion of less than 1%.
- the coarse proportion of particles whose size is over 10 ⁇ m can also be reduced to a proportion of less than 1%.
- This at least one additional classifying process is preferably carried out under a protective gas atmosphere, for example helium, argon, or nitrogen, although this is not intended to represent an exhaustive list of possibilities.
- a protective gas atmosphere for example helium, argon, or nitrogen, although this is not intended to represent an exhaustive list of possibilities.
- the protective gas atmosphere particularly prevents spontaneous powder fires due to the fine particles fP.
- the fifth and sixth process step or the last two process steps ie the dispersion and the separation of fine particles fP and/or the separation of coarse particles gP, can be carried out in a dynamic classifier 10 according to Figures 2 and 3 done together.
- the powdery intermediate product ZP is fed from above to the classifier device or the dynamic classifier 10 via the product addition 1.
- the necessary process air VL is supplied through the classifier air inlet 2, which takes the powdery intermediate product ZP supplied via the product addition 1 and leads it through a large number of adjustable guide vane gaps of the static guide vane basket 3, whereby the intermediate product ZP is dispersed.
- a protective gas is used as the process air VL.
- the intermediate product ZP dispersed in this way is passed through a classifier wheel 4 whose speed can be continuously adjusted, with the particle sizes being separated either into target and coarse material or into target and fine material.
- the optimized classifier wheel design ensures that very high fineness levels can be achieved with just one classifier wheel 4, even at high throughputs.
- the finest particles fP leave the classifier device 10 via the classifier wheel 4, which is installed with a horizontal shaft 8 in the center of the classifier device or the dynamic classifier 10.
- the coarse particles gP are rejected by the classifier wheel 4 and through the helical design and with a partition 5 Provided machine housing 9 is discharged on the back via the coarse material outlet 6 on the underside of the machine housing 9.
- the position of the coarse material flap 7 can be used to regulate the discharge of the coarse particles gP in difficult separation tasks, and thus the cleanliness of the coarse particles gP can be influenced.
- the particles of the target size ZP leave the dynamic classifier 10 together with the coarse material via the coarse material outlet 6.
- the fine particles fP were separated from the particles of the target size ZP and therefore do not form part of the fraction that leaves the dynamic classifier 10 via the coarse material outlet 6.
- the desired target particle size ZG is regulated in particular by regulating the gas flow of the process air VL and/or the speed of the classifier wheel 4. A higher gas flow and/or a lower speed lead to a coarser product, while a lower gas flow and/or a higher one speed lead to a finer product.
- Figure 4 shows the particle size distribution in the intermediate product ZP and in the starting material AM.
- the diagram plots the particle size in ⁇ m against the proportion of the volume density of the respective mixture in %. It is clearly visible here that through the additional process step of dispersing the intermediate product ZP and sifting with subsequent separation of the finest particles fP ⁇ 1 ⁇ m and/or coarse particles gP ⁇ 10 via a dynamic sifter 10, a more homogeneous particle mixture in the starting material AM can be achieved, in which the proportion of fine particles fP is ⁇ 1% of the volume density and in which the proportion of coarse particles gP is also ⁇ 1% of the volume density. In particular, the hatched portions of fine particles fP and coarse particles gP are removed from the powdery intermediate product ZP.
- the starting material AM produced in this way is particularly suitable for the production of sintered rare earth magnets due to the particle size between 1 ⁇ m and 10 ⁇ m, preferably between 2 ⁇ m and 8 ⁇ m, since particularly good magnets can be achieved with these particle sizes of the starting material AM.
- this starting material AM for the production of permanent magnets high (improved) remanence values BR and good (improved) opposing field stability HcJ as well as a significant improvement in the squareness of the demagnetization curve are achieved.
- Figure 5 shows a scanning electron microscope image of the powdery intermediate product ZP and Figure 6 shows a scanning electron micrograph of the starting material AM, as it is produced in various embodiments of the method according to the invention and can be used for the production of rare earth magnets.
- the intermediate product ZP represents a highly inhomogeneous mixture of different particle sizes and in particular also contains a high proportion of fine particles fP Figure 6
- the double-screened starting material AM mainly only contains particles of a target size ZG between 1 ⁇ m and 10 ⁇ m, preferably between 2 ⁇ m and 8 ⁇ m.
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Abstract
Die Erfindung betrifft ein Verfahren zur Herstellung eines pulverförmigen und zur Fertigung von Seltenerd-Magneten vorgesehenen Ausgangsmaterials (AM). Das Verfahren umfasst folgende Schritte:- Zerkleinern einer mindestens ein Seltenerdmetall umfassenden Legierung, wobei aus der einen mindestens ein Seltenerdmetall umfassenden Legierung ein pulverförmiges Zwischenprodukt (ZP) entsteht und- Durchführen mindestens einer auf Partikelgröße und/oder Dichte ausgerichteten Klassierung für das pulverförmige Zwischenprodukt (ZP), wobei eine mittels der mindestens einen Klassierung gebildete Fraktion des pulverförmigen Zwischenproduktes (ZP) das zur Fertigung von Seltenerd-Magneten vorgesehene Ausgangsmaterial (AM) ausbildet.Es ist zudem wenigstens ein dynamischer Sichter vorgesehen. Ein mittels des mindestens statischen Sichters aus dem pulverförmigen Zwischenprodukt (ZP) abgetrennter Anteil dem wenigstens einen dynamischen Sichter (10) zugeführt wird, welcher wenigstens eine dynamische Sichter (10) die wenigstens eine auf Partikelgröße und/oder Dichte ausgerichtete Klassierung für den mittels des mindestens einen statischen Sichters aus dem pulverförmigen Zwischenprodukt (ZP) abgetrennten Anteil umsetzt und hierbei die Fraktion aus dem Anteil abtrennt, welche das zur Fertigung von Seltenerd-Magneten vorgesehene Ausgangsmaterial (AM) ausbildet.The invention relates to a method for producing a powdery starting material (AM) intended for the production of rare earth magnets. The method comprises the following steps: - Crushing an alloy comprising at least one rare earth metal, a powdery intermediate product (ZP) being formed from the alloy comprising at least one rare earth metal, and - Carrying out at least one classification based on particle size and/or density for the powdery intermediate product (ZP ), whereby a fraction of the powdery intermediate product (ZP) formed by means of the at least one classification forms the starting material (AM) intended for the production of rare earth magnets. At least one dynamic classifier is also provided. A portion separated from the powdery intermediate product (ZP) by means of the at least static classifier is fed to the at least one dynamic classifier (10), which at least one dynamic classifier (10) carries out at least one classification based on particle size and/or density for the at least A static classifier implements the portion separated from the powdery intermediate product (ZP) and thereby separates the fraction from the portion that forms the starting material (AM) intended for the production of rare earth magnets.
Description
Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung eines Ausgangsmaterials für die Herstellung von Seltenerd- Magneten, ein Ausgangsmaterial und eine Anlage zur Herstellung eines Ausgangsmaterials für die Herstellung von Seltenerd- Magneten.The present invention relates to a method for producing a starting material for the production of rare earth magnets, a starting material and a system for producing a starting material for the production of rare earth magnets.
Ein Dauermagnet (auch: Permanentmagnet) ist ein Stück eines magnetisierbaren Materials, zum Beispiel Eisen, Kobalt oder Nickel, welches sein statisches Magnetfeld behält, ohne dass man (im Gegensatz zu Elektromagneten) einen elektrischen Stromfluss benötigt. Ein Dauermagnet kann durch die Einwirkung eines Magnetfeldes auf ein ferromagnetisches Material erzeugt werden.A permanent magnet (also: permanent magnet) is a piece of a magnetizable material, for example iron, cobalt or nickel, which maintains its static magnetic field without the need for an electrical current flow (unlike electromagnets). A permanent magnet can be created by applying a magnetic field to a ferromagnetic material.
Unter dem Namen Seltenerd- Magnete fasst man eine Gruppe von Permanentmagneten zusammen, die im Wesentlichen aus Eisenmetallen (Eisen, Cobalt, seltener Nickel) und Seltenerdmetallen (insbesondere Neodym, Samarium, Praseodym, Dysprosium, Terbium, Gadolinium) bestehen. Sie zeichnen sich dadurch aus, dass sie gleichzeitig eine hohe magnetische Remanenzflussdichteund eine hohe magnetische Koerzitivfeldstärke und damit eine hohe magnetische Energiedichte aufweisen.The name rare earth magnets refers to a group of permanent magnets that essentially consist of ferrous metals (iron, cobalt, more rarely nickel) and rare earth metals (especially neodymium, samarium, praseodymium, dysprosium, terbium, gadolinium). They are characterized by the fact that they simultaneously have a high magnetic remanent flux density and a high magnetic coercive field strength and thus a high magnetic energy density.
Eine Legierung aus Neodym, Eisen und Bor (NdFeB) ermöglicht beispielsweise die Herstellung von sehr starken Magneten zu verhältnismäßig günstigen Kosten. Die Herstellung erfolgt über pulvermetallurgische Verfahren, heute aber teilweise auch als kunststoffgebundene Magnete. Lange Zeit waren die Einsatztemperaturen auf 60-120 °C begrenzt. Bei einigen neueren Entwicklungen mit weiteren Zusätzen anderer Seltenerdelemente, insbesondere Dysprosium oder Terbium, kann die Temperaturstabilität auf über 200°C angehoben werden. Zur Erhöhung der Korrosionsstabilität werden oft andere Legierungsbestandteile wie Kobalt hinzulegiert.An alloy of neodymium, iron and boron (NdFeB), for example, enables the production of very strong magnets at a relatively low cost. They are manufactured using powder metallurgy processes, but today they are also sometimes produced using plastic-bonded magnets. For a long time, operating temperatures were limited to 60-120 °C. In some newer developments with additional additions of other rare earth elements, in particular dysprosium or terbium, the temperature stability can be increased to over 200°C. To increase corrosion stability, other alloy components such as cobalt are often added.
Permanentmagnete werden aus kristallinem Pulver hergestellt. Das Magnetpulver wird in Gegenwart eines starken Magnetfelds in eine Form gepresst. Dabei richten sich die Kristalle mit ihrer bevorzugten Magnetisierungsachse in Richtung des Magnetfelds aus. Die Presslinge werden anschließend gesintert. Beim Sintern werden die pulverisierten Bestandteile des Pulvers durch Erwärmung miteinander verbunden oder verdichtet, wobei jedoch keine oder zumindest nicht alle Ausgangsstoffe aufgeschmolzen werden. Dabei werden die Presslinge - oft unter erhöhtem Druck - derart erhitzt, dass die Temperaturen unterhalb der Schmelztemperatur der Hauptkomponenten bleiben, so dass die Gestalt (Form) des Werkstückes erhalten bleibt.Permanent magnets are made from crystalline powder. The magnetic powder is pressed into a mold in the presence of a strong magnetic field. The crystals align themselves with their preferred magnetization axis in the direction of the magnetic field. The compacts are then sintered. During sintering, the pulverized components of the powder are bonded together or compacted by heating, but none or at least not all of the starting materials are melted. The compacts are heated - often under increased pressure - in such a way that the temperatures remain below the melting temperature of the main components, so that the shape (shape) of the workpiece is retained.
Bei der oberhalb von 1000 C liegenden Sintertemperatur geht die nach außen hin wirksame Magnetisierung verloren, weil die thermische Bewegung der Atome zur weitestgehend antiparallelen Ausrichtung der Elementarmagnete in den Kristallen führt. Da die Orientierung der Körner im Sinterverbund jedoch nicht verloren geht, kann die Parallelausrichtung der Elementarströme nach dem Abkühlen der Magnete durch einen ausreichend starken Magnetisierungsimpuls wiederhergestellt werden.At sintering temperatures above 1000 C, the externally effective magnetization is lost because the thermal movement of the atoms leads to the elementary magnets in the crystals being aligned largely antiparallel. However, since the orientation of the grains in the sintered composite is not lost, the parallel alignment of the elementary currents can be restored after the magnets have cooled down by a sufficiently strong magnetization pulse.
Die Herstellung des Magnetpulvers erfolgt insbesondere durch Vermahlen der entsprechenden Legierungen bzw. Bestandteile beispielsweise in Fließbettstrahlmühlen oder ähnlichen Mahlanlagen. In Fließbettstrahlmühlen erfolgt insbesondere eine definierte Feinstvermahlung, zwar mit exakter Oberkornbegrenzung, jedoch mit nicht unerheblichem Anteil an Feinstpartikeln. Die Zerkleinerungsenergie wird hierbei durch Gasstrahlen bereitgestellt.The magnetic powder is produced in particular by grinding the corresponding alloys or components, for example in fluid bed jet mills or similar grinding systems. In fluid bed jet mills, in particular, defined fine grinding takes place, with an exact upper grain limit, but with a not insignificant proportion of fine particles. The comminution energy is provided by gas jets.
Die Praxis hat gezeigt, dass Magnetpulver, welche mittels der aus dem Stand der Technik bekannten Verfahren hergestellt werden können, chemisch sehr reaktiv sind und aus diesem Grunde bereits bei geringen Sauerstoffkonzentrationen mit dem Sauerstoff oder Stickstoff aus der Umgebung reagieren. Hierdurch können mit einer Weiterverarbeitung des Magnetpulvers Pulverbrände einhergehen. Auch hat die Praxis gezeigt, dass sich Magnete, die mittels aus dem Stand der Technik bekannten Magnetpulvern hergestellt werden, häufig nur sehr schlecht orientierten lassen, wodurch die Remanenz der aus den bereits bekannten Magnetpulvern hergestellten Magnete verschlechtert wird. Solche Nachteile können insbesondere mit bzw. bei einem hohen Volumenprozentsatz an Feinanteilen im Magnetpulver einhergehen.Practice has shown that magnetic powders, which can be produced using processes known from the prior art, are chemically very reactive and for this reason react with the oxygen or nitrogen from the environment even at low oxygen concentrations. As a result, further processing of the magnetic powder can result in powder fires. Practice has also shown that magnets that are manufactured using magnetic powders known from the prior art can often be oriented very poorly, which means that the remanence of the magnets manufactured from the already known magnetic powders is impaired. Such disadvantages can be associated, in particular, with or with a high volume percentage of fines in the magnetic powder.
Weiter kann es sein, dass aus den bereits aus dem Stand der Technik bekannten Magnetpulvern hergestellte Magnete aufgrund eines hohen Volumenprozentsatzes an Grobanteil eine verbesserungswürdige Gegenfeldstabilität bzw. Koerzitivfeldstärke besitzen.Furthermore, it may be that magnets made from the magnetic powders already known from the prior art have an opposing field stability or coercive field strength that requires improvement due to a high volume percentage of coarse content.
Die Aufgabe der Erfindung besteht darin, die Herstellung des Ausgangsgemisches zur Herstellung von Seltenerd- Magneten weiter zu optimieren, um damit verbesserte Seltenerd- Magneten herstellen zu können.The object of the invention is to further optimize the production of the starting mixture for the production of rare earth magnets in order to be able to produce improved rare earth magnets.
Die obige Aufgabe wird durch die Gegenstände mit den Merkmalen in den unabhängigen Ansprüchen gelöst. Weitere vorteilhafte Ausgestaltungen werden durch die Unteransprüche beschrieben.The above task is solved by the objects having the features in the independent claims. Further advantageous embodiments are described in the subclaims.
Die Erfindung betrifft ein Verfahren zur Herstellung eines pulverförmigen und zur Fertigung von Seltenerd-Magneten vorgesehenen Ausgangsmaterials.The invention relates to a method for producing a powdery starting material intended for the production of rare earth magnets.
Ein erster Schritt des Verfahrens sieht ein Zerkleinern einer mindestens ein Seltenerdmetall umfassenden Legierung vor, wobei aus der einen mindestens ein Seltenerdmetall umfassenden Legierung ein pulverförmiges Zwischenprodukt entsteht.A first step of the method involves comminution of an alloy comprising at least one rare earth metal, with a powdery intermediate product being formed from the alloy comprising at least one rare earth metal.
Ein weiterer Schritt sieht ein Durchführen mindestens einer auf Partikelgröße und/oder Dichte ausgerichteten Klassierung für das pulverförmige Zwischenprodukt vor, wobei eine mittels der mindestens einen Klassierung gebildete Fraktion des pulverförmigen Zwischenproduktes das zur Fertigung von Seltenerd-Magneten vorgesehene Ausgangsmaterial ausbildet.A further step provides for carrying out at least one classification for the powdery intermediate product based on particle size and/or density, with a fraction of the powdery intermediate product formed by means of the at least one classification forming the starting material intended for the production of rare earth magnets.
Für das Verfahren ist wenigstens ein dynamischer Sichter vorgesehen, welcher wenigstens eine dynamische Sichter wenigstens eine auf Partikelgröße und/oder Dichte ausgerichtete Klassierung für das pulverförmige Zwischenprodukt umsetzt und hierbei die Fraktion aus dem pulverförmigen Zwischenprodukt abtrennt, welche das zur Fertigung von Seltenerd-Magneten vorgesehene Ausgangsmaterial ausbildet.At least one dynamic classifier is provided for the method, which implements at least one dynamic classifier for the powdery intermediate product based on particle size and/or density and thereby separates the fraction from the powdery intermediate product which is the starting material intended for the production of rare earth magnets trains.
In bevorzugten Ausführungsformen kann vorgesehen sein, dass das pulverförmige Zwischenprodukt mindestens einem statischen Sichter zugeführt wird. Hierauf folgend kann ein mittels des mindestens einen statischen Sichters aus dem pulverförmigen Zwischenprodukt abgetrennter Anteil dem wenigstens einen dynamischen Sichter zugeführt werden, welcher wenigstens eine dynamische Sichter die wenigstens eine auf Partikelgröße und/oder Dichte ausgerichtete Klassierung für den mittels des mindestens einen statischen Sichters aus dem pulverförmigen Zwischenprodukt abgetrennten Anteil umsetzt und hierbei die Fraktion aus dem Anteil abtrennt, welche das zur Fertigung von Seltenerd-Magneten vorgesehene Ausgangsmaterial ausbildet.In preferred embodiments it can be provided that the powdery intermediate product is fed to at least one static classifier. Following this, a static classifier can be removed from the at least one The portion separated from the powdery intermediate product is fed to the at least one dynamic classifier, which implements at least one dynamic classifier, which implements the at least one classification based on particle size and/or density for the portion separated from the powdery intermediate product by means of the at least one static classifier, and in this case the fraction from the portion separates, which forms the starting material intended for the production of rare earth magnets.
Auch kann es sein, dass der wenigstens eine dynamische Sichter das pulverförmige Zwischenprodukt sichtet und zudem dispergiert, woraus resultierend die Fraktion aus dem pulverförmigen Zwischenprodukt abgetrennt wird, welche das zur Fertigung von Seltenerd-Magneten vorgesehene Ausgangsmaterial ausbildet.It can also be that the at least one dynamic classifier sifts the powdery intermediate product and also disperses it, from which the fraction is separated from the powdery intermediate product, which forms the starting material intended for the production of rare earth magnets.
Vorstellbar ist darüber hinaus, dass im Rahmen einer ersten auf Partikelgröße und/oder Dichte ausgerichteten Klassierung der wenigstens eine dynamische Sichter Grobgut aus dem pulverförmigen Zwischenprodukt abtrennt und dass im Rahmen einer zweiten auf Partikelgröße und/oder Dichte ausgerichteten Klassierung der wenigstens eine dynamische Sichter Feingut aus dem pulverförmigen Zwischenprodukt abtrennt. Hierbei kann ein vom Feingut und Grobgut abgetrennter Anteil des pulverförmigen Zwischenproduktes die Fraktion bereitstellen, welche das zur Fertigung von Seltenerd-Magneten vorgesehene Ausgangsmaterial ausbildet.It is also conceivable that, as part of a first classification based on particle size and/or density, the at least one dynamic classifier separates coarse material from the powdery intermediate product and that, as part of a second classification based on particle size and/or density, the at least one dynamic classifier separates fine material separated from the powdery intermediate product. Here, a portion of the powdery intermediate product separated from the fine and coarse material can provide the fraction that forms the starting material intended for the production of rare earth magnets.
Es haben sich Ausführungsformen bewährt, bei welchen die erste auf Partikelgröße und/oder Dichte ausgerichtete Klassierung und die zweite auf Partikelgröße und/oder Dichte ausgerichtete Klassierung über genau einen dynamischen Sichter durchgeführt werden. Weiter kann die mindestens ein Seltenerdmetall umfassende Legierung in zwei voneinander getrennten Schritten jeweils vorzugsweise mechanisch zerkleinert werden, wobei aus den Zerkleinerungen in getrennten Schritten das pulverförmige Zwischenprodukt entsteht.Embodiments have proven useful in which the first classification based on particle size and/or density and the second classification based on particle size and/or density are carried out via exactly one dynamic classifier. Furthermore, the alloy comprising at least one rare earth metal can be comminuted, preferably mechanically, in two separate steps, with the powdery intermediate product being formed from the comminutements in separate steps.
Es kann sein, dass der wenigstens eine dynamische Sichter die wenigstens eine auf Partikelgröße und/oder Dichte ausgerichtete Klassierung für das pulverförmige Zwischenprodukt unter Schutzgasatmosphäre umsetzt.It may be that the at least one dynamic classifier implements the at least one classification based on particle size and/or density for the powdery intermediate product under a protective gas atmosphere.
Die Erfindung betrifft zudem ein zur Fertigung von Seltenerd-Magneten vorgesehenes Ausgangsmaterial, welches durch ein Verfahren gemäß einer der vorhergehend beschriebenen Ausführungsformen hergestellt wurde. Bei dem erfindungsgemäßen Ausgangsmaterial liegt ein Anteil an Partikeln > 8µm bei ≤ 2 Volumenprozent, insbesondere in einem Bereich zwischen 0,1 Volumenprozent und 1 Volumenprozent und/oder ein Anteil an Partikeln < 2 µm bei ≤ 2 Volumenprozent und insbesondere in einem Bereich zwischen 0,05 Volumenprozent und 2 Volumenprozent.The invention also relates to a starting material intended for the production of rare earth magnets, which is produced by a method according to one of previously described embodiments were produced. In the starting material according to the invention, a proportion of particles > 8 μm is ≤ 2 percent by volume, in particular in a range between 0.1 percent by volume and 1 percent by volume and / or a proportion of particles < 2 μm is ≤ 2 percent by volume and in particular in a range between 0. 05 percent by volume and 2 percent by volume.
Die Erfindung betrifft darüber hinaus ein Verfahren zur Fertigung von Seltenerd-Magneten. Das Verfahren umfasst folgende Schritte:
- Herstellen eines Ausgangsmaterials mittels eines Verfahrens gemäß einem Ausführungsbeispiel der vorhergehenden Beschreibung,
- Einbringen des Ausgangsmaterials in Formen und Verpressen des Ausgangsmaterials in den Formen, wobei Rohlinge aus dem Ausgangsmaterial entstehen,
- Sintern der Rohlinge und Beaufschlagen gesinterten Rohlinge mit einem Magnetisierungsimpuls, so dass hieraus resultierend die gesinterten und mit einem Magnetisierungsimpuls beaufschlagten Rohlinge als Seltenerd-Magnete ausgebildet sind, optional können die Rohlinge einer mechanischen Bearbeitung unterzogen werden.
- Producing a starting material by means of a method according to an exemplary embodiment of the preceding description,
- Introducing the starting material into molds and pressing the starting material into the molds, creating blanks from the starting material,
- Sintering the blanks and applying a magnetization pulse to the sintered blanks, so that as a result the sintered blanks subjected to a magnetization pulse are designed as rare earth magnets; optionally, the blanks can be subjected to mechanical processing.
Es kann zudem sein, dass mittels des beschriebenen Verfahrens zur Fertigung von Seltenerd-Magneten ein Ausgangsmaterial gemäß vorheriger Beschreibung hergestellt wird und dass dieses Ausgangsmaterial in die Formen eingebracht und verpresst wird.It may also be the case that a starting material is produced according to the previous description using the described method for producing rare earth magnets and that this starting material is introduced into the molds and pressed.
Die Erfindung betrifft darüber hinaus eine Anlage zur Herstellung eines pulverförmigen und zur Fertigung von Seltenerd-Magneten vorgesehenen Ausgangsmaterials. Merkmale, welche vorhergehend bereits zu diversen Ausführungsformen der Verfahren beschrieben wurden, können ebenso bei nachfolgend beschriebener Anlage vorgesehen sein und werden daher nicht redundant erwähnt. Auch können nachfolgend beschriebene Merkmale, welche diverse Ausführungsformen der erfindungsgemäßen Anlage betreffen, ggf. in den vorherig bereits beschriebenen Verfahren vorgesehen sein.The invention also relates to a system for producing a powdery starting material intended for the production of rare earth magnets. Features that have already been described previously for various embodiments of the method can also be provided in the system described below and are therefore not mentioned redundantly. Features described below, which relate to various embodiments of the system according to the invention, can also be provided in the methods already described above.
Die Anlage zur Herstellung eines pulverförmigen und zur Fertigung von Seltenerd-Magneten vorgesehenen Ausgangsmaterials umfasst mindestens eine Zerkleinerungseinrichtung, welche auf eine Erzeugung eines pulverförmigen Zwischenproduktes durch Zerkleinerung einer mindestens ein Seltenerdmetall umfassenden Legierung ausgerichtet ist.The system for producing a powdery starting material intended for the production of rare earth magnets comprises at least one comminution device, which is aimed at producing a powdery intermediate product by comminuting an alloy comprising at least one rare earth metal.
Weiter umfasst die Anlage wenigstens eine Trenneinrichtung, welche über wenigstens eine auf Partikelgröße und/oder Dichte ausgerichtete Klassierung bzw. Sichtung eine Fraktion aus dem pulverförmigen Zwischenprodukt abtrennen kann, die das zur Fertigung von Seltenerd-Magneten vorgesehene Ausgangsmaterial ausbildet.The system further comprises at least one separating device, which can separate a fraction from the powdery intermediate product via at least one classification or sifting based on particle size and/or density, which forms the starting material intended for the production of rare earth magnets.
Es ist vorgesehen, dass die wenigstens eine Trenneinrichtung wenigstens einen dynamischen Sichter umfasst, der über eine auf Partikelgröße und/oder Dichte ausgerichtete Klassierung die Fraktion aus dem pulverförmigen Zwischenprodukt abtrennen kann, die das zur Fertigung von Seltenerd-Magneten vorgesehene Ausgangsmaterial ausbildet.It is envisaged that the at least one separating device comprises at least one dynamic classifier, which can separate the fraction from the powdery intermediate product which forms the starting material intended for the production of rare earth magnets via a classification based on particle size and/or density.
In bevorzugten Ausführungsformen kann vorgesehen sein, dass die wenigstens eine Trenneinrichtung mindestens einen statischen Sichter umfasst, welchem das pulverförmige Zwischenprodukt zuführbar ist. Hierbei können der mindestens eine statische Sichter und der wenigstens eine dynamische Sichter derart miteinander in Verbindung stehen, dass ein mittels des mindestens einen statischen Sichters aus dem zugeführten Zwischenprodukt abgetrennter Anteil dem wenigstens einen dynamischen Sichter zuführbar ist. Der wenigstens eine dynamische Sicher kann sodann ggf. aus dem zugeführten Anteil die Fraktion abtrennen, die das zur Fertigung von Seltenerd-Magneten vorgesehene Ausgangsmaterial ausbildet.In preferred embodiments, it can be provided that the at least one separating device comprises at least one static classifier, to which the powdery intermediate product can be fed. Here, the at least one static classifier and the at least one dynamic classifier can be connected to one another in such a way that a portion separated from the supplied intermediate product by means of the at least one static classifier can be fed to the at least one dynamic classifier. The at least one dynamic safe can then, if necessary, separate the fraction from the supplied portion that forms the starting material intended for the production of rare earth magnets.
Es kann sein, dass der wenigstens eine dynamische Sichter zum Sichten und Dispergieren des zugeführten pulverförmigen Zwischenproduktes ausgebildet ist.It may be that the at least one dynamic classifier is designed to classify and disperse the supplied powdery intermediate product.
Auch kann es sein, dass die mindestens eine Zerkleinerungseinrichtung zwei aufeinanderfolgende Zerkleinerungsmaschinen umfasst, die jeweils zur vorzugsweise mechanischen Zerkleinerung der mindestens ein Seltenerdmetall umfassenden Legierung ausgebildet sind und zur Erzeugung des pulverförmigen Zwischenproduktes aus der mindestens ein Seltenerdmetall umfassenden Legierung miteinander zusammenwirken.It can also be that the at least one comminution device comprises two successive comminution machines, each of which is designed for preferably mechanical comminution of the alloy comprising at least one rare earth metal and interacts with one another to produce the powdery intermediate product from the alloy comprising at least one rare earth metal.
Bewährt haben sich zudem Ausführungsformen, bei welchen der wenigstens eine dynamische Sicher die auf Partikelgröße und/oder Dichte ausgerichtete Klassierung unter Schutzgasatmosphäre umsetzen kann.Embodiments in which the at least one dynamic filter can implement the classification based on particle size and/or density under a protective gas atmosphere have also proven successful.
Das Ausgangsmaterial, welche im Rahmen der vorhergehend beschriebenen Verfahren bzw. mittels der vorhergehend beschriebenen Anlage herstellbar ist, kann im Wesentlichen Partikel eines Zielgrößenbereichs umfassen und kaum Verschmutzungen mit Partikeln aufweisen, die kleiner sind als Partikel eines Zielgrößenbereichs. Diese werden nachfolgend auch als Feinstpartikel bezeichnet. Weiterhin kann das im Rahmen der vorhergehend beschriebenen Verfahren bzw. mittels der vorhergehend beschriebenen Anlage hergestellte Ausgangsmaterial im Wesentlichen kaum Verschmutzungen mit Partikeln, die größer als die Partikel des Zielgrößenbereichs sind, aufweisen. Diese werden nachfolgend auch als Grobpartikel bezeichnet.The starting material, which can be produced within the framework of the previously described methods or by means of the previously described system, can essentially comprise particles of a target size range and hardly have any contamination with particles that are smaller than particles of a target size range. These are also referred to below as fine particles. Furthermore, the starting material produced within the framework of the previously described methods or by means of the previously described system can essentially hardly contain any contamination with particles that are larger than the particles of the target size range. These are also referred to below as coarse particles.
Mit einem Verfahren bzw. einer Anlage gemäß vorhergehender Beschreibung kann insbesondere ein Ausgangsmaterial herstellbar sein, das im Wesentlichen nur Partikel mit einer Größe innerhalb des Zielgrößenbereichs in einer im Wesentlichen homogenen Mischung umfasst. Im Hinblick auf das Ausgangsmaterial, welches mit den vorhergehend beschriebenen Verfahren bzw. mittels der vorhergehend beschriebenen Anlage herstellbar ist, haben sich Ausführungsformen bewährt, bei welchen das Ausgangsmaterial Partikel im Zielgrößenbereich zwischen 1µm und 10µm, insbesondere in einem Zielgrößenbereich zwischen 2µm und 8µm, aufweist. Bei einer Zerkleinerung einer mindestens ein Seltenerd-Metall umfassenden Legierung, lässt sich in der Praxis nicht vermeiden, dass ein Anteil an Feinstpartikeln entsteht, die kleiner sind als der Zielgrößenbereich. Zudem liegt meist ein Anteil an Grobpartikeln vor, die nicht ausreichend zerkleinert worden sind. Hier muss immer ein guter Kompromiss gefunden werden. Eine weitere Vermahlung des Ausgangsmaterials würde zwar zu einer Reduzierung des Anteils an Grobpartikeln führen, gleichzeitig würde sich aber der Anteil an ebenfalls unerwünschten Feinstpartikeln erhöhen. Ein hoher volumenprozentmäßiger Anteil an Feinstpartikeln und/oder Grobpartikeln im Ausgangsmaterial geht mit unerwünschten Eigenschaften der jeweiligen aus dem Ausgangsmaterial hergestellten bzw. gefertigen Seltenerd-Magneten einher.With a method or a system according to the previous description, it can in particular be possible to produce a starting material which essentially only comprises particles with a size within the target size range in a substantially homogeneous mixture. With regard to the starting material, which can be produced with the previously described methods or by means of the previously described system, embodiments have proven successful in which the starting material has particles in the target size range between 1µm and 10µm, in particular in a target size range between 2µm and 8µm. When comminuting an alloy containing at least one rare earth metal, in practice it cannot be avoided that a proportion of fine particles are created that are smaller than the target size range. In addition, there is usually a proportion of coarse particles that have not been sufficiently comminuted. A good compromise always has to be found here. Further grinding of the starting material would lead to a reduction in the proportion of coarse particles, but at the same time the proportion of fine particles, which are also undesirable, would increase. A high volume percentage of fine particles and/or coarse particles in the starting material is associated with undesirable properties of the respective rare earth magnets produced or manufactured from the starting material.
Besonders bevorzugt enthält ein im Rahmen der vorhergehenden Verfahren bzw. mittels der vorhergehend beschriebenen Anlage hergestelltes Ausgangsmaterial ≤ 2 Volumenprozent an Feinstpartikeln, insbesondere ≤ 1 Volumenprozent. Weiterhin kann vorgesehen sein, dass das im Rahmen der vorhergehenden Verfahren bzw. mittels der vorhergehend beschriebenen Anlage hergestellte Ausgangsmaterial ≤ 2 Volumenprozent an Grobpartikeln umfasst, insbesondere ≤ 1 Volumenprozent.Particularly preferably, a starting material produced in the context of the preceding processes or by means of the system described above contains ≤ 2 percent by volume of fine particles, in particular ≤ 1 percent by volume. Furthermore, it can be provided that the starting material produced in the context of the preceding methods or by means of the system described above comprises ≤ 2 percent by volume of coarse particles, in particular ≤ 1 percent by volume.
Gemäß einer bevorzugten Ausführungsform enthält das im Rahmen der vorhergehend beschriebenen Verfahren bzw. mittels der vorhergehend beschriebenen Anlage hergestellte Ausgangsmaterial im Wesentlichen bzw. überwiegend Partikel im Zielgrößenbereich zwischen 2µm und 8µm, wobei ein Anteil an Partikeln, deren Größe oberhalb von 8µm liegt, bei ≤ 2 Volumenprozent liegt, insbesondere in einem Bereich zwischen 0,1 Volumenprozent und 1 Volumenprozent und wobei ein Anteil an Partikeln, deren Größe unterhalb von 2µm liegt bei ≤ 2 Volumenprozent liegt, insbesondere in einem Bereich zwischen 0,05 Volumenprozent und 2 Volumenprozent.According to a preferred embodiment, the starting material produced within the framework of the previously described method or by means of the previously described system essentially or predominantly contains particles in the target size range between 2µm and 8µm, with a proportion of particles whose size is above 8µm being ≤ 2 Percent by volume, in particular in a range between 0.1 percent by volume and 1 percent by volume and where a proportion of particles whose size is below 2 μm is ≤ 2 percent by volume, in particular in a range between 0.05 percent by volume and 2 percent by volume.
Der vorhergehend bereits erwähnte und als Bestandteil der erfindungsgemäßen Verfahren bzw. der erfindungsgemäßen Anlage ausgebildete wenigstens eine dynamische Sichter kann einen Klassierrotor umfassen. Eine Drehzahl des Klassierrotors kann ggf. in Abhängigkeit einer für das herzustellende Ausgangsmaterial gewünschten Partikelgrößenverteilung gesteuert bzw. geregelt werden. Hierzu kann eine Steuer- und/oder Regeleinheit vorgesehen sein, welche mit dem wenigstens einen dynamischen Sichter in Verbindung steht. Auf der Steuer- und/oder Regeleinheit kann ein Algorithmus abgelegt sein, über welchen die Steuer- und/oder Regeleinheit unter Berücksichtigung der jeweiligen für das herzustellende Ausgangsmaterial gewünschten Partikelgrößenverteilung eine Drehzahl des als Bestandteils des wenigstens einen dynamischen Sichters ausgebildeten Klassierrotors selbständig regelt bzw. steuert.The at least one dynamic classifier already mentioned above and designed as part of the method according to the invention or the system according to the invention can comprise a classifying rotor. A speed of the classifying rotor can, if necessary, be controlled or regulated depending on a particle size distribution desired for the starting material to be produced. For this purpose, a control and/or regulating unit can be provided, which is connected to the at least one dynamic classifier. An algorithm can be stored on the control and/or regulating unit, via which the control and/or regulating unit independently regulates or controls a speed of the classifying rotor designed as a component of the at least one dynamic classifier, taking into account the respective particle size distribution desired for the starting material to be produced .
Der vorherig bereits erwähnte und in diversen Ausführungsformen eines erfindungsgemäßen Verfahrens bzw. einer erfindungsgemäßen Anlage vorgesehene mindestens eine statische Sichter kann ggf. durch mindestens seinen Zyklonklassierer ausgebildet sein. Durch den mindestens einen Zyklonklassierer kann ggf. bereits eine Reduzierung des Anteils an Feinstpartikeln erzielt werden. Ein via den mindestens einen statischen Sichter bzw. den mindestens einen Zyklonklassierer abgetrenntes pulveriges Gemisch, welches nachfolgend auch als pulverförmiges Zwischenprodukt bezeichnet wird, enthält auch nach der Abtrennung von Feinstpartikeln in der Regel immer noch bis zu 10 Volumenprozent an Feinstpartikeln und/oder bis zu 10 Volumenprozent an Grobpartikeln. Die Feinstanteile, die in einem solchen pulverförmigen Zwischenprodukt notgedrungen immer vorhanden sind, wirken sich somit in mehrfacher Hinsicht nachteilig auf die Eigenschaften der daraus hergestellten Seltenerd-Magnete aus.The previously mentioned at least one static classifier, which is provided in various embodiments of a method according to the invention or a system according to the invention, can optionally be designed by at least its cyclone classifier. The at least one cyclone classifier can possibly achieve a reduction in the proportion of fine particles. A separated via the at least one static classifier or the at least one cyclone classifier Powdery mixture, which is also referred to below as a powdery intermediate product, usually still contains up to 10 percent by volume of fine particles and / or up to 10 percent by volume of coarse particles even after the fine particles have been separated. The fine particles, which are necessarily always present in such a powdery intermediate product, have a detrimental effect on the properties of the rare earth magnets made from them in several respects.
Um die Partikelzusammensetzung noch weiter zu verbessern, wird das gemahlene und ggf. teilweise bereits über den mindestens einen statischen Sichter von Feinstpartikeln anteilig befreite pulverförmige Zwischenprodukt noch mindestens einem weiteren Sichterprozess, umgesetzt durch wenigstens einen dynamischen Sichter, unterworfen. Um diesen Sichterprozess effizient durchzuführen zu können, haben sich Ausführungsformen bewährt, bei welchen das pulverförmige Zwischenprodukt zunächst dispergiert wird und anschließend eine Klassierung nach Partikelgröße und/oder Dichte für das dispergierte pulverförmige Zwischenprodukt durchgeführt wird. Diese Dispergierung und Klassierung nach Partikelgröße und/oder Dichte können in genau einem dynamischen Sichter durchgeführt wird. Über den wenigstens einen dynamischen Sichter bzw. über den genau einen dynamischen Sichter können sodann Feinstpartikel und/oder Grobpartikel aus dem pulverförmigen Zwischenprodukt abgetrennt werden.In order to improve the particle composition even further, the ground powder intermediate product, which has possibly already been partially freed of fine particles via the at least one static classifier, is subjected to at least one further classifier process, implemented by at least one dynamic classifier. In order to be able to carry out this classifying process efficiently, embodiments have proven useful in which the powdery intermediate product is first dispersed and then a classification according to particle size and/or density is carried out for the dispersed powdery intermediate product. This dispersion and classification according to particle size and/or density can be carried out in exactly one dynamic classifier. Fine particles and/or coarse particles can then be separated from the powdery intermediate product via the at least one dynamic classifier or exactly one dynamic classifier.
D.h. das Verfahren kann folgende Schritte einzeln oder in Kombination umfassen:
- Dispersion des Zwischenproduktes UND/ODER
- erneute Abtrennung von Feinstpartikeln und/oder Grobpartikeln.
- Dispersion of the intermediate AND/OR
- renewed separation of fine particles and/or coarse particles.
Vorzugsweise kann somit vorgesehen sein, dass die Dispersion des Zwischenproduktes und das erneute Abtrennen von Feinstpartikeln und/oder Grobpartikeln innerhalb einer einzigen Vorrichtung, insbesondere innerhalb eines einzigen dynamischen Sichters, durchgeführt werden. Aufgrund der hohen chemischen Reaktivität von ggf. in hoher Konzentration im pulverförmigen Zwischenprodukt vorhandenen Feinstpartikeln, kann der einzige dynamische Sichter eine Dispergierung und/oder Sichtung ggf. unter Schutzgasatmosphäre umsetzen. Als Schutzgas findet beispielsweise Helium, Argon, Stickstoff o.ä. Verwendung.It can therefore preferably be provided that the dispersion of the intermediate product and the renewed separation of fine particles and/or coarse particles are carried out within a single device, in particular within a single dynamic classifier. Due to the high chemical reactivity of fine particles that may be present in high concentrations in the powdery intermediate product, the only dynamic classifier can If necessary, carry out dispersion and/or sifting under an inert gas atmosphere. Helium, argon, nitrogen, etc. are used as protective gases.
Das mindestens eine als Bestandteil der Legierung ausgebildete Seltenerdmetall kann beispielsweise durch Eisen und/oder Bor ausgebildet sein. Beispielsweise kann es sich bei der mindestens ein Seltenerdmetall umfassenden Legierung um eine NdFeB- Legierung handeln. Über die oben beschriebenen Verfahrensschritte bzw. mittels der bereits beschriebenen Anlage kann aus dieser mindestens ein Seltenerd-Metall umfassenden Legierung ein Ausgangsmaterial hergestellt werden, das im Wesentlichen nur Partikel im Zielgrößenbereich zwischen 1µm bis 10µm, vorzugsweise zwischen 2µm bis 8µm, umfasst. Vorzugsweise umfasst das Ausgangsgemisch ≥ 95 Volumenprozent, insbesondere ≥ 98 Volumenprozent an Partikeln im Zielgrößenbereich, welcher Zielgrößenbereich von 2µm bis 8µm festgesetzt ist.The at least one rare earth metal formed as a component of the alloy can be formed, for example, by iron and/or boron. For example, the alloy comprising at least one rare earth metal can be an NdFeB alloy. Using the process steps described above or by means of the system already described, a starting material can be produced from this alloy comprising at least one rare earth metal, which essentially only comprises particles in the target size range between 1µm to 10µm, preferably between 2µm to 8µm. The starting mixture preferably comprises ≥ 95 percent by volume, in particular ≥ 98 percent by volume, of particles in the target size range, which target size range is set from 2 μm to 8 μm.
Die bereits beschriebene Anlage kann eine Vorrichtung zur Grobzerkleinerung einer mindestens ein Seltenerdmetall umfassenden Legierung umfassen. Eine unter Zuhilfenahme der Vorrichtung zur Grobzerkleinerung ggf. aus der mindestens ein Seltenerdmetall umfassenden Legierung gebildete grobe Pulverfraktion kann ggf. in einer als Bestandteil der Anlage ggf. ausgebildeten Vorrichtung zur Feinzerkleinerung zu einer feinen Pulverfraktion vermahlen werden, wobei die feine Pulverfraktion das pulverförmige Zwischenprodukt ausgebildet. Beispielsweise kann die Vorrichtung zur Feinzerkleinerung als Fließbettstrahlmühle ausgebildet sein.The system already described can include a device for the coarse comminution of an alloy comprising at least one rare earth metal. A coarse powder fraction, possibly formed from the alloy comprising at least one rare earth metal with the aid of the device for coarse comminution, can optionally be ground into a fine powder fraction in a device for fine comminution, which may be designed as part of the system, the fine powder fraction forming the powdery intermediate product. For example, the device for fine comminution can be designed as a fluid bed jet mill.
Im Folgenden sollen Ausführungsbeispiele die Erfindung und ihre Vorteile anhand der beigefügten Figuren näher erläutern. Die Größenverhältnisse der einzelnen Elemente zueinander in den Figuren entsprechen nicht immer den realen Größenverhältnissen, da einige Formen vereinfacht und andere Formen zur besseren Veranschaulichung vergrößert im Verhältnis zu anderen Elementen dargestellt sind. Nachfolgend beschriebene Merkmale sind nicht eng mit dem jeweiligen Ausführungsbeispiel verknüpft sondern können im allgemeinen Zusammenhang Verwendung finden.
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zeigt schematisch Verfahrensschritte zur Herstellung eines Ausgangsmaterials zur Fertigung von Seltenerd- Magneten, wie sie in diversen Ausführungsformen jeweils einzeln oder in der gezeigten Kombination vorgesehen sein können;Figur 1 -
zeigt einen Querschnitt durch einen dynamischen Sichter, wie er in diversen Ausführungsformen des erfindungsgemäßen Verfahrens sowie in diversen Ausführungsformen der erfindungsgemäßen Anlage vorgesehen sein kann.Figur 2 -
zeigt einen seitlichen Querschnitt durch den dynamischenFigur 3Sichter nach Figur 2 . -
stellt einer für diverse Ausführungsformen des erfindungsgemäßen Verfahrens bzw. der erfindungsgemäßen Anlage denkbare Partikelgrößenverteilung eines pulverförmigen Zwischenproduktes einer denkbaren Partikelgrößenverteilung eines zur Fertigung von Seltenerd-Magneten vorgesehenen Ausgangsmaterials gegenüber;Figur 4 -
zeigt eine rasterelektronenmikroskopische Aufnahme, wie sie für das pulverförmige Zwischenprodukt ausgebildet sein kann;Figur 5 -
zeigt eine rasterelektronenmikroskopische Aufnahme, eines Ausgangsmaterials, wie es mittels des erfindungsgemäßen Verfahrens bzw. der erfindungsgemäßen Anlage in diversen Ausführungsformen hergestellt werden kann.Figur 6
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Figure 1 shows schematically process steps for producing a starting material for producing rare earth magnets, as they can be provided individually or in the combination shown in various embodiments; -
Figure 2 shows a cross section through a dynamic classifier, as can be provided in various embodiments of the method according to the invention and in various embodiments of the system according to the invention. -
Figure 3 shows a side cross section through the dynamic classifierFigure 2 . -
Figure 4 compares a conceivable particle size distribution of a powdery intermediate product for various embodiments of the method according to the invention or the system according to the invention with a conceivable particle size distribution of a starting material intended for the production of rare earth magnets; -
Figure 5 shows a scanning electron micrograph as it can be designed for the powdery intermediate product; -
Figure 6 shows a scanning electron micrograph of a starting material, as can be produced in various embodiments using the method according to the invention or the system according to the invention.
Für gleiche oder gleich wirkende Elemente der Erfindung werden identische Bezugszeichen verwendet. Ferner werden der Übersicht halber nur Bezugszeichen in den einzelnen Figuren dargestellt, die für die Beschreibung der jeweiligen Figur erforderlich sind. Die dargestellten Ausführungsformen stellen lediglich Beispiele dar, wie die Erfindung ausgestaltet sein kann und stellen keine abschließende Begrenzung dar.Identical reference numbers are used for elements of the invention that are the same or have the same effect. Furthermore, for the sake of clarity, only reference numbers that are necessary for the description of the respective figure are shown in the individual figures. The illustrated embodiments merely represent examples of how the invention can be designed and do not represent a final limitation.
Die Partikel fP des Feinstanteils sind auf Grund ihrer Feinheit chemisch sehr reaktiv und reagieren bereits bei geringsten Sauerstoffkonzentrationen mit dem Sauerstoff oder auch mit dem Stickstoff aus der Umgebung. Diese Feinstpartikel fP können bei der weiteren Verarbeitung der Pulver spontane Pulverbrände hervorrufen. Ein weiterer Nachteil der Feinstpartikel fP besteht darin, dass diese feinen Pulverteilchen sich in den üblicherweise zur Verfügung stehenden Magnetfeldern und Pressvorrichtungen (Größenordnung etwa 10 - 20 kOe) nur sehr schlecht orientieren lassen und deshalb die Remanenz der daraus hergestellten Magnete verschlechtern. Aus diesem Grund werden in einem vierten bzw. zusätzlichen Verfahrensschritt Feinstanteile, insbesondere Partikel mit einem Durchmesser von ≤ 1-2µm, aus der feinen Pulverfraktion fPF entfernt. Hierzu wird das Gemisch beispielsweise im Anschluss an die Grobvermahlung und Feinvermahlung nach Ziffern 1. und 2. durch einen Zyklon geführt, dass den Feinstanteil über einen geeigneten Gasstrom mitführt und dabei von dem Gemisch abtrennt. Dadurch wird das Zwischenprodukt ZP gebildet. Dieses enthält aber immer noch einen nicht unerheblichen Anteil von bis zu 10% an Feinstpartikeln kleiner ca. 1 µm bis 2µm.The particles fP of the fine fraction are chemically very reactive due to their fineness and react with the oxygen or even with the nitrogen from the environment even at the lowest oxygen concentrations. These fine particles fP can cause spontaneous powder fires during further processing of the powder. Another disadvantage of the finest particles fP is that these fine powder particles are very difficult to orient in the magnetic fields and pressing devices that are usually available (of the order of magnitude of approximately 10 - 20 kOe) and therefore worsen the remanence of the magnets made from them. For this reason, in a fourth or additional process step, fine particles, in particular particles with a diameter of ≤ 1-2 μm, are removed from the fine powder fraction fPF. For this purpose, for example, following the coarse grinding and fine grinding according to
Um diese verbleibenden Anteile an Feinstpartikeln fP ≤ 1 µm bis 2µm und/oder Grobpartikeln gP zwischen 10µm und 15µm möglichst vollständig zu entfernen, wird das Zwischenprodukt ZP mindestens einem weiteren Sichterprozess unterzogen, um ungewünschte Feinstpartikel fP oder Grobpartikeln gP oder Feinstpartikel fP und Grobpartikel gP zu entfernen und somit die Homogenität der Partikel in der Zielgröße ZG weiter zu verbessern, insbesondere um als Ausgangsmaterial AM ein Pulvergemisch zu erhalten, das im Wesentlichen nur noch Partikel mit Partikelgrößen in einem Zielbereich zwischen etwa 2µm bis 8µm umfasst, da diese Partikel in magnetischer Hinsicht die beste Pulverfraktion darstellen. Sämtlich weiteren Schritte, welche in zeitlicher Hinsicht an den Schritt nach Ziffer 4. Anschließen, werden unter Zuhilfenahme eines dynamischen Sichters 10 (vgl.
Die Partikel mit der Zielgröße ZG zwischen 2µm bis 8µm sind chemisch hinreichend stabil, so dass sie im normalen Herstellungsprozess keinerlei zusätzliche Oxidation bewirken. Zudem lassen sie sich mit den üblichen Magnetfeldern gut orientieren. Sie tragen somit wesentlich zum Erreichen einer hohen Remanenz der hergestellten Magnete bei und sind deshalb erwünscht, notwendig und nützlich. Je mehr Pulverteilchen von dieser Zielgröße ZG vorhanden sind, umso besser sind die Magnetwerte (Remanenz Br und Gegenfeldstabilität HcJ) der daraus hergestellten Magnete.The particles with the target size ZG between 2µm to 8µm are chemically sufficiently stable so that they do not cause any additional oxidation in the normal manufacturing process. They can also be easily oriented using the usual magnetic fields. They therefore contribute significantly to achieving a high remanence of the magnets produced and are therefore desirable, necessary and useful. The more powder particles of this target size ZG are present, the better the magnetic values (remanence Br and opposing field stability HcJ) of the magnets made from them.
In einem weiteren bzw. vorliegend 5. Verfahrensschritt wird das pulverförmige Zwischenprodukt ZP dispergiert, um eine möglichst homogene Verteilung der unterschiedlichen Partikel des Zwischenproduktes ZP herzustellen. Dabei werden insbesondere molekulare und magnetische Anziehungskräfte zwischen den Partikeln überwunden und eine der Dispergierung folgende erneute Sichtung und Abtrennung von Partikel des Feinstanteils und/oder Partikel des Grobanteils möglich. Auch für diesen Verfahrensschritt wird ein dynamischer Sichter 10 (vgl.
Das dispergierte pulverförmige Zwischenprodukt ZP wird erneut gesichtet und Partikel des Feinstanteils und/oder Partikel des Grobanteils werden dabei entfernt. Dadurch wird eine optimierte Trennung von Feinst- und Grobanteil zur gewünschten Partikel- Zielgröße ZG hergestellt. Der Feinstanteil von Partikeln, deren Größe kleiner 1 µm beträgt, wird dabei auf einen Anteil von weniger als 1 % reduziert. Alternativ oder zusätzlich kann der Grobanteil von Partikeln, deren Größe über 10µm liegt, ebenfalls auf einen Anteil von weniger als 1 % reduziert werden.The dispersed powdery intermediate product ZP is sifted again and particles of the fine fraction and/or particles of the coarse fraction are removed. This creates an optimized separation of the finest and coarse particles to achieve the desired target particle size ZG. The fine proportion of particles whose size is less than 1 µm is reduced to a proportion of less than 1%. Alternatively or additionally, the coarse proportion of particles whose size is over 10µm can also be reduced to a proportion of less than 1%.
Dieser mindestens eine zusätzliche Sichtersprozess wird vorzugsweise unter Schutzgasatmosphäre durchgeführt, beispielsweise unter Helium, Argon, oder Stickstoff, wobei dies keine abschließende Aufzählung der Möglichkeiten darstellen soll. Die Schutzgasatmosphäre verhindert insbesondere spontane Pulverbrände aufgrund der Feinstpartikel fP.This at least one additional classifying process is preferably carried out under a protective gas atmosphere, for example helium, argon, or nitrogen, although this is not intended to represent an exhaustive list of possibilities. The protective gas atmosphere particularly prevents spontaneous powder fires due to the fine particles fP.
Besonders bevorzugt können der fünfte und sechste Verfahrensschritt bzw. die beiden letzten Verfahrensschritte, d.h. die Dispersion und die Abtrennung von Feinstpartikeln fP und/oder die Abtrennung von Grobpartikeln gP in einem dynamischen Sichter 10 gemäß
Im Hinblick auf die Ausführungsform eines dynamischen Sichters 1 nach
Das derart aufdispergierte Zwischenprodukt ZP wird über ein in der Drehzahl stufenlos einstellbares Sichterrad 4 geleitet, wobei die Trennung der Partikelgrößen entweder in Ziel- und Grobgut oder aber in Ziel- und Feinstgut erfolgt.The intermediate product ZP dispersed in this way is passed through a
Durch das optimierte Sichterraddesign ist gewährleistet, dass mit nur einem Sichterrad 4 sehr hohe Feinheiten auch bei hohen Durchsätzen erreicht werden können. Die Feinstpartikel fP verlassen die Sichtervorrichtung 10 über das mit horizontaler Welle 8 eingebaute Sichterrad 4 im Zentrum der Sichtervorrichtung bzw. des dynamischen Sichters 10. Die groben Partikel gP werden vom Sichterrad 4 abgewiesen und durch das schraubenförmig ausgebildete und mit einer Trennwand 5 versehene Maschinengehäuse 9 rückseitig über den Grobgutaustritt 6 an der Unterseite des Maschinengehäuses 9 ausgetragen. Über die Stellung der Grobgutklappe 7 kann der Austrag der Grobpartikel gP bei schwierigen Trennaufgaben geregelt, und so die Sauberkeit der Grobpartikel gP beeinflusst werden. Die Partikel der Zielgröße ZP verlassen zusammen mit dem Grobgut den dynamischen Sichter 10 über den Grobgutaustritt 6. Der Feinstpartikel fP wurden von den Partikeln der Zielgröße ZP abgetrennt und bilden somit keinen Bestandteil der Fraktion, welche den dynamischen Sichter 10 über den Grobgutaustritt 6 verlässt.The optimized classifier wheel design ensures that very high fineness levels can be achieved with just one
Die Regulierung der gewünschten Zielpartikelgröße ZG erfolgt hierbei insbesondere über eine Regulierung des Gasstroms der Verfahrensluft VL und/oder der Drehzahl des Sichterrads 4. Ein höherer Gasstrom und/oder eine niedrigere Drehzahl führen zu einem gröberen Produkt, während ein niedrigerer Gasstrom und/oder eine höhere Drehzahl zu einem feineren Produkt führen.The desired target particle size ZG is regulated in particular by regulating the gas flow of the process air VL and/or the speed of the
Zusätzlich zeigt die
Das derart hergestellte Ausgangsmaterial AM eignet sich aufgrund der zwischen 1µm und 10µm, vorzugsweise zwischen 2µm und 8µm, liegenden Partikelgröße besonders für die Herstellung von gesinterten Seltenerd- Magneten, da bei diesen Partikelgrößen des Ausgangsmaterials AM besonders gute Magnetwerde erzielt werden können. Insbesondere werden mit diesem Ausgangsmaterial AM für die Herstellung von Permanentmagneten hohe (verbesserte) Remanenzwerte BR und eine gute (verbesserte) Gegenfeldstabilität HcJ sowie eine deutliche Verbesserung der Rechteckigkeit der Entmagnetisierungskurve erzielt.The starting material AM produced in this way is particularly suitable for the production of sintered rare earth magnets due to the particle size between 1µm and 10µm, preferably between 2µm and 8µm, since particularly good magnets can be achieved with these particle sizes of the starting material AM. In particular, with this starting material AM for the production of permanent magnets, high (improved) remanence values BR and good (improved) opposing field stability HcJ as well as a significant improvement in the squareness of the demagnetization curve are achieved.
Die Ausführungsformen, Beispiele und Varianten der vorhergehenden Absätze, die Ansprüche oder die folgende Beschreibung und die Figuren, einschließlich ihrer verschiedenen Ansichten oder jeweiligen individuellen Merkmale, können unabhängig voneinander oder in beliebiger Kombination verwendet werden. Merkmale, die in Verbindung mit einer Ausführungsform beschrieben werden, sind für alle Ausführungsformen anwendbar, sofern die Merkmale nicht unvereinbar sind. Die Erfindung wurde unter Bezugnahme auf bevorzugte Ausführungsformen beschrieben. Es ist für einen Fachmann vorstellbar, dass Abwandlungen oder Änderungen der Erfindung gemacht werden können, ohne dabei den Schutzbereich der nachstehenden Ansprüche zu verlassen. Es ist möglich, einige der Komponenten oder Merkmale eines der Beispiele in Kombination mit Merkmalen oder Komponenten eines anderen Beispiels anzuwenden.The embodiments, examples and variants of the preceding paragraphs, the claims or the following description and the figures, including their various views or respective individual features, may be used independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless the features are inconsistent. The invention has been described with reference to preferred embodiments. It will be conceivable to a person skilled in the art that modifications or changes may be made to the invention without departing from the scope of the following claims. It is possible to apply some of the components or features of one of the examples in combination with features or components of another example.
- 11
- ProduktzugabeProduct addition
- 22
- SichterlufteintrittClassifier air inlet
- 33
- LeitschaufelkorbGuide vane basket
- 44
- Sichterradsifter wheel
- 55
- Trennwandpartition wall
- 66
- GrobgutaustrittCoarse material exit
- 77
- GrobgutklappeCoarse material flap
- 88th
- WelleWave
- 99
- MaschinengehäuseMachine housing
- 1010
- SichtervorrichtungClassifying device
- 1111
- SpaltgaszuführungFission gas supply
- AMAT THE
- AusgangsmaterialSource material
- fPfP
- feinste Partikel / Feinstpartikelfinest particles/fine particles
- fPFfPF
- feine Pulverfraktionfine powder fraction
- gPGP
- grobe Partikel Grobpartikelcoarse particles coarse particles
- gPFgPF
- grobe Pulverfraktioncoarse powder fraction
- VLVL
- VerfahrensluftProcess air
- ZGZG
- ZielgrößeTarget size
- ZPZP
- Zwischenproduktintermediate product
- SGSG
- Spaltgasfission gas
Claims (14)
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DE102017116272.0A DE102017116272A1 (en) | 2017-07-19 | 2017-07-19 | METHOD AND APPARATUS FOR MANUFACTURING AN INITIAL MATERIAL FOR THE PRODUCTION OF RARE-DIGITAL MAGNETS |
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