JP2001207203A - METHOD FOR PRODUCING Fe-Si-Al POWDER FOR DUST CORE - Google Patents
METHOD FOR PRODUCING Fe-Si-Al POWDER FOR DUST COREInfo
- Publication number
- JP2001207203A JP2001207203A JP2000013682A JP2000013682A JP2001207203A JP 2001207203 A JP2001207203 A JP 2001207203A JP 2000013682 A JP2000013682 A JP 2000013682A JP 2000013682 A JP2000013682 A JP 2000013682A JP 2001207203 A JP2001207203 A JP 2001207203A
- Authority
- JP
- Japan
- Prior art keywords
- powder
- less
- dust core
- producing
- particle size
- 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.)
- Pending
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/147—Alloys characterised by their composition
- H01F1/14766—Fe-Si based alloys
- H01F1/14791—Fe-Si-Al based alloys, e.g. Sendust
Landscapes
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Powder Metallurgy (AREA)
- Soft Magnetic Materials (AREA)
- Manufacture Of Metal Powder And Suspensions Thereof (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、圧粉磁心用Ｆｅ−
Ｓｉ−Ａｌ系粉末を製造する方法に関するものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an Fe-
The present invention relates to a method for producing a Si-Al-based powder.
【０００２】[0002]
【従来の技術】従来、Ｆｅ−Ｓｉ−Ａｌ系合金圧粉磁心
は、鉄圧粉磁心およびＦｅ−Ｎｉ合金圧粉磁心とともに
高周波数帯域において、安定して高い透磁率を示すこと
から、特にＦｅ−Ｓｉ−Ａｌ系合金圧粉磁心は、鉄圧粉
磁心より高周波特性に優れている他、直流重畳特性に優
れていること、およびＮｉ，Ｍｏ等の高価な原料を含ま
ず、Ｆｅ−Ｎｉ合金圧粉磁心よりは低廉であることか
ら、フェライトコアに変わる材料として注目されてい
る。2. Description of the Related Art Conventionally, Fe-Si-Al based alloy dust cores, together with iron dust cores and Fe-Ni alloy dust cores, exhibit a stable and high magnetic permeability in a high frequency band. -Si-Al based alloy dust cores are superior to iron dust cores in terms of high frequency characteristics and DC direct current characteristics, and do not contain expensive raw materials such as Ni and Mo. Since it is less expensive than dust cores, it is attracting attention as a material to replace ferrite cores.
【０００３】そこで、このＦｅ−Ｓｉ−Ａｌ系合金圧粉
磁心は一般にインゴットを溶製し、これを拡散焼鈍して
Ａｌ，Ｓｉの偏析を低減した上で粗粉砕し、さらに、数
段階の粉砕工程を経て原料粉末とするもので、全て粉砕
粉であるために、充填性が低下する。これに替わって、
ガスアトマイズ法により製造される方法が提案されて
い。しかし、ガスアトマイズには分級が必要で、一定粒
度以上の粉末は使用できず生産性が低く、また、全て球
状粉であるため、形状効果がでず透磁率は大きくないの
が実状である。[0003] Therefore, this Fe-Si-Al-based alloy powder core is generally produced by melting an ingot, diffusion annealing it to reduce segregation of Al and Si, and then coarsely pulverizing it. Since the raw material powder is obtained through the process, and all are pulverized powder, the filling property is reduced. Instead,
A method of manufacturing by a gas atomizing method has been proposed. However, gas atomization requires classification, and powders with a certain particle size or more cannot be used, resulting in low productivity. Further, since all powders are spherical powders, the shape effect is not obtained and the magnetic permeability is not large.
【０００４】これらのガスアトマイズ法の改良として、
例えば、特開昭６２−２５０６０７号公報に示されるよ
うに、Ｆｅ−Ｓｉ−Ａｌ系合金の粉末の表面を無機絶縁
物質で被覆し、加圧成形後熱処理してなるＦｅ−Ｓｉ−
Ａｌ系合金圧粉磁心の製造方法や、特開平１１−１８９
８０３号公報のように、ガスアトマイズ法により製造さ
れた重量でＡｌ：４．５〜８．５％、Ｓｉ：７．５〜
９．５％、残部Ｆｅを主成分とするＦｅ−Ａｌ−Ｓｉ系
軟磁性合金粉末が知られている。[0004] As an improvement of these gas atomizing methods,
For example, as disclosed in JP-A-62-250607, the surface of an Fe-Si-Al-based alloy powder is coated with an inorganic insulating material, and the powder is subjected to heat treatment after pressure molding.
Japanese Patent Laid-Open No. 11-189
No. 803, Al: 4.5 to 8.5% by weight manufactured by gas atomization, Si: 7.5 to 7.5
There is known an Fe-Al-Si soft magnetic alloy powder containing 9.5% with the balance being Fe as a main component.
【０００５】[0005]
【発明が解決しようとする課題】上述したように、従来
はＦｅ−Ｓｉ−Ａｌ系合金粉末を鋳造−粉砕法で作製し
た場合には、偏析があるため高周波特性が低下すると共
に全て粉砕粉であることから充填性が悪いと言う問題が
ある。このために、鋳造−粉砕法に替わって、ガスアト
マイズ法が提案されたものである。しかし、ガスアトマ
イズによって作製された粉末を分級して使用される場合
には、一定粒度以上の粉末は使用されないため生産性が
低下する一方、全て球状であるため形状効果がでず透磁
率はそれ程大きくならないと言う問題がある。そのため
に、上記特開昭６２−２５０６０７号公報の場合のよう
に、ガスアトマイズによって作製された粉末を粉砕する
方法が採られているが、全て粉砕粉であるため、充填性
が低下すると言う問題がある。また、特開平１１−１８
９８０３号公報の場合にも、渦電流損失の問題から、あ
る粒度以下の粉末しか使えず、生産性が悪いと言う問題
がある。As described above, conventionally, when Fe-Si-Al-based alloy powder is produced by a casting-pulverizing method, high-frequency characteristics are reduced due to segregation, and all powders are pulverized. For this reason, there is a problem that the filling property is poor. For this reason, a gas atomizing method has been proposed in place of the casting-grinding method. However, when powders produced by gas atomization are classified and used, productivity is reduced because powders having a certain particle size or more are not used, but since all particles are spherical, the shape effect does not appear and the magnetic permeability is so large. There is a problem that it must not be. For this purpose, as in the case of the above-mentioned Japanese Patent Application Laid-Open No. 62-250607, a method of pulverizing powder produced by gas atomization has been adopted. However, since all powders are pulverized powder, there is a problem that the filling property is reduced. is there. Also, JP-A-11-18
Also in the case of Japanese Patent No. 9803, there is a problem that only powder having a certain particle size or less can be used due to the problem of eddy current loss, and the productivity is poor.
【０００６】[0006]
【課題を解決するための手段】上述したような問題を解
消するため、発明者らは鋭意開発を進めた結果、全ての
球状粉末または粉砕粉末のものではなく、ある最適な範
囲の球状粉を得ることにより、コア特性が優れ、かつ生
産性に優れた圧粉磁心用Ｆｅ−Ａｌ−Ｓｉ系粉末の製造
方法を提供するものである。その発明の要旨とするとこ
ろは、Ｆｅ−Ｓｉ−Ａｌ系合金粉末を用いた圧粉磁心の
製造方法において、Ｆｅ−Ｓｉ−Ａｌ系合金の球状粉を
ガスアトマイズにより作製した後、その粉末を粉砕し得
られた粒度が２００μｍ以下でアスペクト比が１．１以
下の粉末が全体の３０ｗｔ％以上、７０ｗｔ％以下含ま
れることを特徴とするＦｅ−Ｓｉ−Ａｌ系圧粉磁心用粉
末の製造方法にある。Means for Solving the Problems In order to solve the above-mentioned problems, the present inventors have intensively developed and as a result, not all spherical powders or ground powders, but spherical powders in a certain optimum range. The present invention provides a method for producing an Fe—Al—Si powder for a dust core having excellent core characteristics and excellent productivity. The gist of the invention is that in a method of manufacturing a dust core using Fe-Si-Al-based alloy powder, a spherical powder of Fe-Si-Al-based alloy is produced by gas atomization, and then the powder is pulverized. The method for producing a powder for an Fe-Si-Al-based dust core is characterized in that the powder having an obtained particle size of 200 µm or less and an aspect ratio of 1.1 or less is contained in an amount of 30 wt% or more and 70 wt% or less. .
【０００７】[0007]
【発明の実施の形態】以下、本発明について図面に従っ
て詳細に説明する。本発明において、Ｆｅ−Ｓｉ−Ａｌ
系合金の球状粉をガスアトマイズにより作製した後、そ
の粉末を粉砕し得られた粒度が２００μｍ以下でアスペ
クト比が１．１以下の粉末が全体の３０ｗｔ％以上、７
０ｗｔ％以下とした理由は、ガスアトマイズによる球状
粉末によって偏析の少ない粉末を作製し、これを粉砕工
程の導入によって生産性の向上と形状効果による透磁率
の向上を図ると共に、粒度を２００μｍ以下にすること
により、渦電流発生面積の抑制を図るものである。DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the drawings. In the present invention, Fe-Si-Al
After the spherical powder of the base alloy is produced by gas atomization, the powder obtained by pulverizing the powder has a particle size of 200 μm or less and an aspect ratio of 1.1 or less.
The reason for setting the content to 0% by weight or less is that a powder with less segregation is produced by a spherical powder by gas atomization, and the introduction of a pulverizing step improves productivity and the magnetic permeability by a shape effect, and reduces the particle size to 200 μm or less. Thus, the eddy current generation area is suppressed.
【０００８】また、アスペクト比が１．１以下の粉末が
全体の３０ｗｔ％以上、７０ｗｔ％以下にした理由は、
粉末のアスペクト比を１．１以下と小さくすることによ
り、成形時の充填率が向上することを見出した。１．１
未満であると充填性が悪く、透磁率が低下する。そのた
めアスペクト比を１．１以下とする。また、図１に示す
ように、そのアスペクト比が１．１以下の粉末を３０ｗ
ｔ％以上、７０ｗｔ％以下の範囲において、透磁率の優
れていることが判る。すなわち、図１は本発明に係る球
状粉の混合割合と透磁率との関係を示すもので、粉砕し
得られた粒度が２００μｍ以下でアスペクト比が１．１
以下の粉末が全体の３０ｗｔ％以上、７０ｗｔ％以下の
場合に透磁率の優れていることが判る。The reason why the powder having an aspect ratio of 1.1 or less is set to 30 wt% or more and 70 wt% or less of the whole is as follows.
It has been found that the filling factor at the time of molding is improved by reducing the aspect ratio of the powder to 1.1 or less. 1.1
If it is less than this, the filling property is poor and the magnetic permeability decreases. Therefore, the aspect ratio is set to 1.1 or less. Also, as shown in FIG. 1, powder having an aspect ratio of 1.1 or less
It can be seen that the magnetic permeability is excellent in the range of t% or more and 70 wt% or less. That is, FIG. 1 shows the relationship between the mixing ratio of the spherical powder according to the present invention and the magnetic permeability, wherein the particle size obtained by grinding is 200 μm or less and the aspect ratio is 1.1.
It can be seen that the magnetic permeability is excellent when the following powder is 30 wt% or more and 70 wt% or less of the whole.
【０００９】[0009]
【実施例】Ｆｅ−９．６Ｓｉ−５．７Ａｌ合金をガスア
トマイズにより作製し、ボールミルにより２００μｍ以
下で球状粉が全体の３０〜７０ｗｔ％になるように粉砕
した。得られた粉末をＳｉ系樹脂１．５ｗｔ％混合し成
形圧１０ｔ／ｃｍ2 でリング状試料（φ１０〜１５ｍ
ｍ、高さ３ｍｍ）を６５０℃×３０ｍｉｎで熱処理しれ
巻線を得た。その特性評価の透磁率は、ＬＣＲメーター
にて１００ＫＨｚで測定し、磁性損失はＢＨアナライザ
ーで１００ＫＨｚ−０．１ｔにて測定した。EXAMPLE An Fe-9.6Si-5.7Al alloy was produced by gas atomization, and pulverized by a ball mill so that the spherical powder had a particle size of 200 μm or less and 30 to 70 wt% of the whole. The resulting powder Si-based resin 1.5 wt% mixed molding pressure 10t / cm 2 in a ring-shaped sample (Fai10～15m
m, height 3 mm) was heat-treated at 650 ° C. × 30 min to obtain a winding. The magnetic permeability of the property evaluation was measured at 100 KHz with an LCR meter, and the magnetic loss was measured at 100 KHz-0.1 t with a BH analyzer.
【００１０】その結果を表１に示す。Ｎｏ１〜５は本発
明例であり、Ｎｏ６〜１０は比較例である。これから判
るように、本発明例は比較例に比べて透磁率の優れてい
ることが判る。すなわち、比較例Ｎｏ６およびＮｏ７
は、粉砕粉が大きすぎて充填性が悪く、そのため透磁率
が低下した。また、比較例Ｎｏ８およびＮｏ９は、形状
効果の低下により透磁率が低下した。さらに、比較例Ｎ
ｏ１０は、渦電流発生面積が大きくなったことにより、
磁気損失が大きくなった。The results are shown in Table 1. Nos. 1 to 5 are examples of the present invention, and Nos. 6 to 10 are comparative examples. As can be seen from this, it can be seen that the present invention example is superior in magnetic permeability to the comparative example. That is, Comparative Examples No. 6 and No. 7
In the case of the powder, the pulverized powder was too large and the filling property was poor, so that the magnetic permeability was lowered. In Comparative Examples No. 8 and No. 9, the magnetic permeability decreased due to the decrease in the shape effect. Further, Comparative Example N
o10 is due to the increased eddy current generation area,
Magnetic loss increased.
【００１１】[0011]
【表１】 [Table 1]
【００１２】[0012]
【発明の効果】以上述べたように、本発明により高周波
特性に優れたＦｅ−Ｓｉ−Ａｌ系圧粉磁心材を高い生産
性で製造することが可能となり、工業上極めて有利であ
る。As described above, the present invention makes it possible to produce Fe-Si-Al-based dust core materials having excellent high-frequency characteristics with high productivity, which is extremely industrially advantageous.
【図１】本発明に係る球状粉の混合割合と透磁率との関
係を示す図である。FIG. 1 is a diagram showing the relationship between the mixing ratio of spherical powder according to the present invention and magnetic permeability.
───────────────────────────────────────────────────── フロントページの続き Ｆターム(参考） 4K017 BA06 BB01 BB16 CA03 CA07 DA02 EA03 EB01 4K018 AA26 BB01 BB04 BD01 KA44 5E041 AA04 BB05 CA01 HB07 HB17 NN06 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4K017 BA06 BB01 BB16 CA03 CA07 DA02 EA03 EB01 4K018 AA26 BB01 BB04 BD01 KA44 5E041 AA04 BB05 CA01 HB07 HB17 NN06
Claims (1)
粉磁心の製造方法において、Ｆｅ−Ｓｉ−Ａｌ系合金の
球状粉をガスアトマイズにより作製した後、その粉末を
粉砕し得られた粒度が２００μｍ以下でアスペクト比が
１．１以下の粉末が全体の３０ｗｔ％以上、７０ｗｔ％
以下含まれることを特徴とするＦｅ−Ｓｉ−Ａｌ系圧粉
磁心用粉末の製造方法。In a method for manufacturing a dust core using an Fe-Si-Al alloy powder, a spherical powder of an Fe-Si-Al alloy is produced by gas atomization, and then the powder is ground to obtain a particle size. Powder having a particle size of 200 μm or less and an aspect ratio of 1.1 or less is 30% by weight or more and 70% by weight
A method for producing a powder for an Fe-Si-Al-based dust core, which is included below.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000013682A JP2001207203A (en) | 2000-01-24 | 2000-01-24 | METHOD FOR PRODUCING Fe-Si-Al POWDER FOR DUST CORE |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000013682A JP2001207203A (en) | 2000-01-24 | 2000-01-24 | METHOD FOR PRODUCING Fe-Si-Al POWDER FOR DUST CORE |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JP2001207203A true JP2001207203A (en) | 2001-07-31 |
Family
ID=18541238
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2000013682A Pending JP2001207203A (en) | 2000-01-24 | 2000-01-24 | METHOD FOR PRODUCING Fe-Si-Al POWDER FOR DUST CORE |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP2001207203A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2020015936A (en) * | 2018-07-24 | 2020-01-30 | 山陽特殊製鋼株式会社 | Powder for magnetic member |
-
2000
- 2000-01-24 JP JP2000013682A patent/JP2001207203A/en active Pending
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2020015936A (en) * | 2018-07-24 | 2020-01-30 | 山陽特殊製鋼株式会社 | Powder for magnetic member |
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