JP2015529004A - 希土類永久磁石粉末、ボンド磁石及び当該ボンド磁石を応用するデバイス - Google Patents
希土類永久磁石粉末、ボンド磁石及び当該ボンド磁石を応用するデバイス Download PDFInfo
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Abstract
Description
(1)サマリウムの蒸気圧が低いので、製造中に多く揮発されて合金製造コストは不安定になってしまう。揮発されたサマリウムは酸化しやすく、燃焼しやすく、安全事故をもたらしやすい。また、揮発されたサマリウムによって管路を塞いで、真空システムに大きな損害をもたらしてしまう。
(2)サマリウム合金の粘度が大きく、急冷中に銅輪との湿潤性が悪いので、合金液が飛散し、急冷のシート表面の液流動が不安定で、表面が平坦せず、合金の相構造とミクロ組織が均一でなくなってしまい、製造されたサマリウム−鉄−窒素系希土類永久磁石粉末の磁気性能を低下させている。これは、現在、当該材料の汎用を阻害する主な原因でもある。
NdxT100-x-y-aCyNa (I)
ここで、4≦x≦12で、0.1≦y≦2で、10≦a≦25である。
NdxAwT100-x-y-z-aCyBzNa (II)
ここで、TはFe又はFeCoで、AはZr及び/又はHfで、4≦x+w≦12、1≦w≦5、0.1≦z≦2、10≦a≦25、0.1≦z/w≦0.5、0.1≦y≦2である。
NdxT100-x-y-aCyNa (I)
ここで、4≦x≦12、0.1≦y≦2、10≦a≦25である。一般式(I)の構造を有する希土類永久磁石粉末は、水冷ローラとの間の湿潤性が良好で、最終的に製造される希土類永久磁石粉末の磁気性能も良好であるメリットを有する。
NdxAwT100-x-y-z-aCyBzNa (II)
ここで、TはFe又はFeCoで、AはZr及び/又はHfであって、且つ4≦x+w≦12、1≦w≦5、0.1≦z≦2、10≦a≦25、0.1≦z/w≦0.5、0.1≦y≦2である。このような希土類永久磁石粉末は、水冷ローラとの間の湿潤性が優れ、最終的に製造される希土類永久磁石粉末の磁気性能が優れるメリットを有する。
(1)まず、一定成分の合金原料を調和させ、中間周波数、アーク等の方式で溶解して合金鋳塊を得て、(2)粗く砕いた後の合金塊を誘導溶解してから合金液を形成し、合金液を急冷してシート状の合金粉末を得て、(3)得られた合金粉末に一定の温度及び時間の結晶化処理を行って、その後、350〜550℃程度で浸窒及び/又は浸炭処理を行い、窒素源は工業用純窒素と、水素とアンモニアとを混合したガス等である。(4)希土類永久磁石粉末を得る。
X線回折法で確認した結果、以下の実施例S1〜S71で製造される希土類永久磁石粉末における硬質磁性相のメイン相はいずれもTbCu7構造である。以下、希土類永久磁石粉末の成分、結晶粒サイズ、結晶粒分布、磁石粉末の性能を詳しく説明する。
希土類合金粉末の成分は、溶解した合金粉末を浸窒処理して得られる。磁石粉末の成分は浸窒処理後の磁石粉末の成分で、成分を原子百分率で表する。
平均結晶粒サイズの表示方法は、電子顕微鏡で材料のミクロ組織の写真を撮影して、写真の中で硬質磁性相のTbCu7構造の結晶粒及び軟質磁性相α-Fe相の結晶粒を観察した。具体的な方法は、N個の同種類の結晶粒の総断面面積Sを統計した後、断面面積Sを一つの円の面積に等価し、円の直径を求めると、平均結晶粒サイズσになり、その単位はnmで、計算式は以下の通りである。
磁石粉末の性能は、振動試料型磁力計(VSM)で検出する。
ここで、Brは残留磁気で、単位はkGsであって、Hcjは固有保磁力で、単位はkOeであって、(BH)mは磁気エネルギー積で、単位はMGOeである。
粗さは、粗さ測定機で測定する。
一、NdxT100-x-y-aCyNa系希土類永久磁石粉末について
比例に応じて表1の実施例1〜16に記載の金属を混合してから誘導溶解炉に投入し、Arガスの保護で、溶解して合金鋳塊を得て、合金鋳塊を粗く砕いた後、急冷炉に投入して急冷を行い、保護ガスはArガスで、噴射圧力は55kPaで、ノズルは2つで、断面面積は0.85mm2で、水冷ローラの線速度は50m/sで、銅輪の直径は300mmで、急冷後にシート状の合金粉末を得た。
比例に応じて表2の実施例17〜36に記載の金属を混合してから誘導溶解炉に投入し、Arガスの保護で、溶解して合金鋳塊を得て、合金鋳塊を粗く砕いた後、急冷炉に投入して急冷を行い、保護ガスはArガスで、噴射圧力は20kPaで、ノズル数は2つで、断面面積は0.75mm2で、水冷ローラの線速度は55m/sで、銅輪の直径は300mmで、急冷後にシート状の合金粉末を得た。
元素Nd、元素C、元素N、元素T(TはFe又はFeCo)、及び元素M(ここで、MはTi、V、Cr、Ni、Cu、Nb、Mo、Ta、W、Al、Ga、Siの中の少なくとも一種類である)を用いて製造した希土類永久磁石粉末について
元素Nd、元素C、元素N、元素T(TはFe又はFeCo)、元素A、元素B、及び元素M(ここで、MはTi、V、Cr、Ni、Cu、Nb、Mo、Ta、W、Al、Ga、Siの中の少なくとも一種類である)を用いて製造した希土類永久磁石粉末について
比例に応じて表5の実施例S64〜S71に記載の関連する希土類及び遷移金属を混合してから誘導溶解炉に投入し、Arガスの保護で溶解して合金鋳塊を得て、合金鋳塊を粗く砕いた後、急冷炉に投入して急冷を行い、保護ガスはArガスで、噴射圧力は45kPaで、ノズル数は4つで、断面面積は0.75mm2で、水冷ローラの線速度は60m/sで、銅輪の直径は300mmで、急冷後にシート状の合金粉末を得た。
NdxAwT100-x-y-z-aCyBzNa (II)
ここで、TはFe又はFeCoで、AはZr及び/又はHfで、4≦x+w≦12、1≦w≦5、0.1≦z≦2、10≦a≦25、0.1≦z/w≦0.5、0.1≦y≦2である。
Claims (15)
- 4〜12at.%のNdと、0.1〜2at.%のCと、10〜25at.%のNと、62.2〜85.9at.%のT(ここで、TはFe又はFeCoである)とを含み、TbCu7構造の硬質磁性相をメイン相とすることを特徴とする希土類永久磁石粉末。
- 以下の一般式(I)
NdxT100-x-y-aCyNa (I)
(ここで、4≦x≦12で、0.1≦y≦2で、10≦a≦25である)
の構造を有することを特徴とする請求項1に記載の希土類永久磁石粉末。 - 1〜5at.%の元素Aと、0.1〜2at.%のBとをさらに含み、前記元素AはZr及び/又はHfであって、前記Bの含有量と前記元素Aの含有量との比は0.1〜0.5であることを特徴とする請求項1に記載の希土類永久磁石粉末。
- 前記Bの含有量の範囲は0.3〜2at.%であることを特徴とする請求項3に記載の希土類永久磁石粉末。
- 前記元素Ndと前記元素Aの含有量は前記希土類永久磁石粉末の総含有量の4〜12at.%であって、且つ、前記希土類永久磁石粉末において、元素Cの含有量と、元素Ndと元素Aの含有量の合計との比は0.03〜0.15であることを特徴とする請求項3に記載の希土類永久磁石粉末。
- 前記希土類永久磁石粉末において、元素Cの含有量と、元素Ndと元素Aの含有量の合計との比は0.05〜0.12であることを特徴とする請求項5に記載の希土類永久磁石粉末。
- 下記一般式(II)
NdxAwT100-x-y-z-aCyBzNa (II)
(ここで、TはFe又はFeCoで、AはZr及び/又はHfで、4≦x+w≦12、1≦w≦5、0.1≦z≦2、10≦a≦25、0.1≦z/w≦0.5、0.1≦y≦2である)
の構造を有することを特徴とする請求項5に記載の希土類永久磁石粉末。 - 0.3〜10at.%のMをさらに含み、MはTi、V、Cr、Ni、Cu、Nb、Mo、Ta、W、Al、Ga、Siの中の少なくとも一種類であることを特徴とする請求項1、3乃至6の中のいずれか一項に記載の希土類永久磁石粉末。
- Mの含有量は0.5〜8at.%であることを特徴とする請求項8に記載の希土類永久磁石粉末。
- Mの含有量は0.5〜5at.%で、前記MはNb、Ga、Al、Siの中の少なくとも一種類であることを特徴とする請求項9に記載の希土類永久磁石粉末。
- ローラと接触する面の粗さRaは2.8μm以下であって、前記ローラと接触する面の粗さRaが1.6μm以下であることが好ましいことを特徴とする請求項1乃至10のいずれか一項に記載の希土類永久磁石粉末。
- 平均結晶粒サイズは3〜100nmであることを特徴とする請求項1乃至11のいずれか一項に記載の希土類永久磁石粉末。
- 元素Ndの一部分はSm及び/又はCeに置換され、Sm及び/又はCeの含有量が0.5〜4.0at.%であることを特徴とする請求項1乃至12のいずれか一項に記載の希土類永久磁石粉末。
- 請求項1乃至13のいずれか一項に記載の希土類永久磁石粉末とボンド剤とを接着してなることを特徴とするボンド磁石。
- 請求項14に記載のボンド磁石を応用することを特徴とするデバイス。
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