JP2011060975A - 磁石成形体およびその製造方法 - Google Patents
磁石成形体およびその製造方法 Download PDFInfo
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- JP2011060975A JP2011060975A JP2009208621A JP2009208621A JP2011060975A JP 2011060975 A JP2011060975 A JP 2011060975A JP 2009208621 A JP2009208621 A JP 2009208621A JP 2009208621 A JP2009208621 A JP 2009208621A JP 2011060975 A JP2011060975 A JP 2011060975A
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- magnet
- rare earth
- particles
- magnetic powder
- earth magnet
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- 238000001420 photoelectron spectroscopy Methods 0.000 description 2
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Classifications
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/08—Metallic powder characterised by particles having an amorphous microstructure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/16—Metallic particles coated with a non-metal
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
- B22F3/14—Both compacting and sintering simultaneously
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/07—Alloys based on nickel or cobalt based on cobalt
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/005—Ferrous alloys, e.g. steel alloys containing rare earths, i.e. Sc, Y, Lanthanides
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/032—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials
- H01F1/04—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
- H01F1/0571—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes
- H01F1/0572—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 with a protective layer
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
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Abstract
【解決手段】本発明の希土類磁石成形体は、磁石粒子と当該磁石粒子間に存在する絶縁相とを含む。そして、Dy、Tb、Pr、およびHoからなる群から選択される1種または2種以上の元素が偏析した偏析領域が磁石粒子内部に分散して存在する。
【選択図】図1
Description
本工程では、Dy、Tb、Pr、およびHoからなる群から選択される1種または2種以上の元素の単体またはその合金を、原料磁粉の表面に被覆して表面修飾原料磁粉を得る。
本工程では、上述した第1工程において得られた表面修飾原料磁粉を磁場中で磁気配向しながら加熱雰囲気下で加圧成形する。これにより、異方性希土類磁石が得られる。
本工程では、上述した第2工程において得られた異方性希土類磁石を粉砕して得られる磁石粒子の表面に絶縁相を被覆する。これにより、磁石成形前駆体が得られる。
本工程では、上述した第3工程において得られた磁石成形前駆体を加圧下で加熱する。これにより、希土類磁石成形体が完成する。
原料磁粉として、HDDR法を用いて調製したNd−Fe−B系異方性磁石の粉末を用いた。具体的な調製の手順は以下の通りである。
希土類アルコキシドとして、ジスプロシウムトリイソプロポキシドに代えてプラセオジウムトリイソプロポキシドを用いてPr酸化物からなる絶縁相を形成したこと以外は、上述した実施例1と同様の手法により、希土類磁石成形体を得た。なお、プラセオジウム表面処理液のPr濃度は、都度ICPにて分析し、磁石粒子10gに対して、合計40mgの塗布量になるように、溶液塗布量を調整した。
原料磁粉として、HDDR法により作製された原料磁粉に代えて、焼結磁石用の原料磁粉を用いたこと以外は、上述した実施例1と同様の手法により、希土類磁石成形体を得た。
原料磁粉を表面修飾して表面修飾原料磁粉を得る際に、合金のスパッタリングに代えて、DyCo合金の水素化物の粉末を原料磁粉と混合して当該粉末を溶融するという手法を採用したこと以外は、上述した実施例3と同様の手法により、希土類磁石成形体を得た。
スパッタリングのターゲット材として、φ100×5t(mm)のDy純金属を用いたこと以外は、上述した実施例3と同様の手法により、希土類磁石成形体を得た。
原料磁粉を表面修飾して表面修飾原料磁粉を得る際に、合金のスパッタリングに代えて、DyCo合金の水素化物の粉末を原料磁粉と混合して当該粉末を溶融するという手法を採用したこと以外は、上述した実施例1と同様の手法により、希土類磁石成形体を得た。なお、表面修飾原料磁粉を得る具体的な手法については、上述した実施例4において説明したとおりである。
磁石粒子の表面に絶縁相を被覆する際に、真空蒸着により絶縁相を被覆するという手法を採用したこと以外は、上述した実施例6と同様の手法により、希土類磁石成形体を得た。
スパッタリングのターゲット材として、Dy−Tb−Pr−Co合金を用いたこと以外は、上述した実施例1と同様の手法により、希土類磁石成形体を得た。
希土類アルコキシドとして、ジスプロシウムトリイソプロポキシドに代えてイットリウムトリイソプロポキシドを用いてY酸化物からなる絶縁相を形成したこと以外は、上述した実施例6と同様の手法により、希土類磁石成形体を得た。
スパッタリングのターゲット材として、上述した実施例5において用いたDy純金属を用い、磁石粒子への絶縁相の被覆を上述した実施例9と同様の手法により実施したこと以外は、上述した実施例1と同様の手法により、希土類磁石成形体を得た。
カソード電極として、Dy金属に代えて30%Tb−15%Pr−10%Ho−bal.Co合金を用いたこと以外は、上述した実施例7と同様の手法により、希土類磁石成形体を得た。なお、上記合金については、Tb、Pr、HoのCo合金を真空アーク溶解にて母合金として調製し、ICPにて濃度分析を行った上で、所定の濃度になるように母合金を混合して、高周波真空溶解にて合金を溶製した。得られた鋳造合金から、機械加工にてφ8mmの電極を加工した。
磁石粒子に絶縁相を被覆して磁石成形前駆体へと加工する際に、ボールミルを用いて磁石粒子にバレル研磨を行ったこと以外は、上述した実施例6と同様の手法により、希土類磁石成形体を得た。なお、バレル研磨の具体的な手法は以下のとおりである。
磁石粒子へ絶縁相を被覆して磁石成形前駆体へと加工する前の時点で、上述した実施例12と同様の手法により、磁石粒子にバレル研磨を行ったこと以外は、上述した実施例7と同様の手法により、希土類磁石成形体を得た。
磁石粒子へ絶縁相を被覆して磁石成形前駆体へと加工する前の時点で、上述した実施例12と同様の手法により、磁石粒子にバレル研磨を行ったこと以外は、上述した実施例1と同様の手法により、希土類磁石成形体を得た。
磁石粒子へ絶縁相を被覆して磁石成形前駆体へと加工する前の時点で、上述した実施例12と同様の手法により、磁石粒子にバレル研磨を行ったこと以外は、上述した実施例5と同様の手法により、希土類磁石成形体を得た。
磁石粒子へ絶縁相を被覆して磁石成形前駆体へと加工する前の時点で、上述した実施例12と同様の手法により、磁石粒子にバレル研磨を行ったこと以外は、上述した実施例3と同様の手法により、希土類磁石成形体を得た。
Dy濃度の異なる2種類の原料磁粉の混合粉末をバルク化し、粉砕したものを磁石粒子として用いたこと以外は、上述した実施例1と同様の手法により、希土類磁石成形体を得た。
原料磁粉へのDyCoNd合金の塗布による表面修飾、および、磁石粒子への絶縁相の被覆を行わなかったこと以外は、上述した実施例1と同様の手法により、希土類磁石成形体を得た。
原料磁粉へのDyCoNd合金の塗布による表面修飾を行わなかったこと以外は、上述した実施例1と同様の手法により、希土類磁石成形体を得た。本実施例において得られた希土類磁石成形体の組織観察結果を、偏析領域が認められない例として図6に示す。
DyCo合金の水素化物を用いた原料磁粉の表面修飾を行わなかったこと以外は、上述した実施例6と同様の手法により、希土類磁石成形体を得た。
DyCo合金の水素化物を用いた原料磁粉の表面修飾、および、磁石粒子への絶縁相の被覆を行わなかったこと以外は、上述した実施例4と同様の手法により、希土類磁石成形体を得た。
DyCo合金の水素化物を用いた原料磁粉の表面修飾を行わなかったこと以外は、上述した実施例4と同様の手法により、希土類磁石成形体を得た。
DyCo合金の水素化物を用いた原料磁粉の表面修飾を行わなかったこと以外は、上述した実施例12と同様の手法により、希土類磁石成形体を得た。
DyCoNd合金の被覆による原料磁粉の表面修飾を行わなかったこと以外は、上述した実施例16と同様の手法により、希土類磁石成形体を作製した。
2 希土類磁石粒子、
3 絶縁相、
4 偏析領域、
5 凝集領域、
11 u相巻線、
12 u相巻線、
13 v相巻線、
14 v相巻線、
15 w相巻線、
16 w相巻線、
17 アルミケース、
18 ステータ、
19 磁石、
20 ロータ鉄、
21 軸。
Claims (12)
- 磁石粒子と前記磁石粒子間に存在する絶縁相とを含む希土類磁石成形体であって、
Dy、Tb、Pr、およびHoからなる群から選択される1種または2種以上の元素が偏析した偏析領域が前記磁石粒子内部に分散して存在することを特徴とする、希土類磁石成形体。 - 自発磁化可能な粒径を有し、平均粒径が前記磁石粒子の平均粒径よりも小さい磁石微粒子が凝集した凝集領域が、前記磁石粒子の外周部の少なくとも一部に存在する、請求項1に記載の希土類磁石成形体。
- 前記磁石微粒子が前記絶縁相と混合されてなる領域が存在する、請求項2に記載の希土類磁石成形体
- 前記偏析領域がCoを含む、請求項1〜3のいずれか1項に記載の希土類磁石成形体。
- 前記偏析領域がNdをさらに含む、請求項4に記載の希土類磁石成形体。
- 前記磁石粒子が、HDDR法を用いて製造された原料磁石粉末を加工することにより作製されたものである、請求項1〜5のいずれか1項に記載の希土類磁石成形体。
- 前記絶縁相が、Nd、Dy、Tb、Pr、およびHoからなる群から選択される1種または2種以上の元素の酸化物を含有する、請求項1〜6のいずれか1項に記載の希土類磁石成形体。
- Dy、Tb、Pr、およびHoからなる群から選択される1種または2種以上の元素の単体またはその合金を、原料磁粉の表面に被覆して表面修飾原料磁粉を得る工程と、
得られた表面修飾原料磁粉を磁場中で磁気配向しながら加熱雰囲気下で加圧成形することにより、異方性希土類磁石を得る工程と、
得られた異方性希土類磁石を粉砕して得られる磁石粒子の表面に絶縁相を被覆することにより、磁石成形前駆体を得る工程と、
得られた磁石成形前駆体を加圧下で加熱する工程と、
を含む、希土類磁石成形体の製造方法。 - 第1原料磁粉と、前記原料磁粉の一部の元素をDy、Tb、Pr、およびHoからなる群から選択される1種または2種以上の元素で置換した第2原料磁粉との混合磁粉を、磁場中で磁気配向しながら加熱雰囲気下で加圧成形することにより、異方性希土類磁石を得る工程と、
得られた異方性希土類磁石を粉砕して得られる磁石粒子の表面に絶縁相を被覆することにより、磁石成形前駆体を得る工程と、
得られた磁石成形前駆体を加圧下で加熱する工程と、
を含む、希土類磁石成形体の製造方法。 - Dy、Tb、Pr、およびHoからなる群から選択される1種または2種以上の元素の単体またはその合金を、原料磁粉の表面に被覆して表面修飾原料磁粉を得る工程と、
得られた表面修飾原料磁粉を磁場中で磁気配向しながら加熱雰囲気下で加圧成形することにより、異方性希土類磁石を得る工程と、
得られた異方性希土類磁石を粉砕して得られる磁石粒子と磁石微粒子とを混合してこれらを一体化させ、得られた磁石粒子の表面に絶縁相を被覆することにより、磁石成形前駆体を得る工程と、
得られた磁石成形前駆体を加圧下で加熱する工程と、
を含む、希土類磁石成形体の製造方法。 - 第1原料磁粉と、前記原料磁粉の一部の元素をDy、Tb、Pr、およびHoからなる群から選択される1種または2種以上の元素で置換した第2原料磁粉との混合磁粉を、磁場中で磁気配向しながら加熱雰囲気下で加圧成形することにより、異方性希土類磁石を得る工程と、
得られた異方性希土類磁石を粉砕して得られる磁石粒子と磁石微粒子とを混合してこれらを一体化させ、得られた磁石粒子の表面に絶縁相を被覆することにより、磁石成形前駆体を得る工程と、
得られた磁石成形前駆体を加圧下で加熱する工程と、
を含む、希土類磁石成形体の製造方法。 - 請求項1〜7のいずれか1項に記載の磁性成形体、または請求項8〜11のいずれか1項に記載の製造方法により製造された磁性成形体を用いたモータ。
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2009208621A JP5515539B2 (ja) | 2009-09-09 | 2009-09-09 | 磁石成形体およびその製造方法 |
EP10815232.3A EP2477199B1 (en) | 2009-09-09 | 2010-08-04 | Rare-earth magnet molding and method for manufacturing the same |
US13/392,365 US10287656B2 (en) | 2009-09-09 | 2010-08-04 | Rare earth magnet molding and method for manufacturing the same |
PCT/JP2010/063162 WO2011030635A1 (ja) | 2009-09-09 | 2010-08-04 | 希土類磁石成形体およびその製造方法 |
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JP7268432B2 (ja) | 2019-03-22 | 2023-05-08 | 株式会社プロテリアル | R-t-b系焼結磁石の製造方法 |
WO2021132476A1 (ja) * | 2019-12-26 | 2021-07-01 | 日立金属株式会社 | R-t-b系焼結磁石の製造方法およびr-t-b系焼結磁石 |
JP6947344B1 (ja) * | 2019-12-26 | 2021-10-13 | 日立金属株式会社 | R−t−b系焼結磁石の製造方法およびr−t−b系焼結磁石 |
JP2023047305A (ja) * | 2021-09-24 | 2023-04-05 | 煙台東星磁性材料株式有限公司 | Nd-Fe-B系磁性体及びその製造方法 |
JP7325921B2 (ja) | 2021-09-24 | 2023-08-15 | 煙台東星磁性材料株式有限公司 | Nd-Fe-B系磁性体及びその製造方法 |
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CN102483991A (zh) | 2012-05-30 |
WO2011030635A1 (ja) | 2011-03-17 |
EP2477199A4 (en) | 2016-11-30 |
JP5515539B2 (ja) | 2014-06-11 |
CN102483991B (zh) | 2015-04-01 |
US10287656B2 (en) | 2019-05-14 |
EP2477199A1 (en) | 2012-07-18 |
EP2477199B1 (en) | 2019-05-22 |
US20120153759A1 (en) | 2012-06-21 |
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