JP2018505540A - 非磁性合金を含む熱間加圧変形磁石及びその製造方法 - Google Patents
非磁性合金を含む熱間加圧変形磁石及びその製造方法 Download PDFInfo
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Abstract
Description
前記非磁性合金の適用可能性を制限するわけではないが、使用頻度やその他の事情などを考慮すると、例えば、それらの合金の共融点が一般的に400〜700℃であるNd系合金やPr系合金などを適用することが好ましい。
原材料のNd−Fe−B系粉末(Nd30B0.9Co4.1Ga0.5FeBal.)を溶融し、当該溶融液を高速で回転する冷却ロールに注入してリボン状の合金を作製した(溶融紡糸工程)。当該ローリング工程で生成されたリボン状のインゴットをスタンプミルでミリングして約200μmの大きさになるように粉砕し、磁性粉末を作製した。
非磁性合金としてNd0.84Cu0.16を磁性粉末に対してそれぞれ0.5重量%(実施例2−1)、1.0重量%(実施例2−2)及び1.5重量%(実施例2−3)添加し、当該粉末をそれぞれの磁性粉末(上記実施例1で作製したもの)と乾式で混合した。
非磁性合金としてNd0.84Cu0.16(重量%)の代わりにPr0.84Cu0.16を用いたことを除いては、上記実施例2と同じ方法で異方性熱間加圧変形磁石を製造した。
上記実施例2(実施例2−1、2−2及び2−3)において加圧焼結を行った焼結体に対して、約575℃の温度で約2時間追加熱処理を行ったことを除いては、上記実施例2と同じ方法で熱間加圧変形磁石(それぞれ実施例4−1〜4−3)を製造した。
上記実施例1で製造した磁性粉末に非磁性合金を添加しないこと以外は、上記実施例2と同様に製造した。
上記実施例2及び3の熱間加圧変形磁石、並びに上記比較例1に対して、その内部構造を透過電子顕微鏡(TEM)により撮影し、その写真を図1に示す。図1から、上記比較例1の磁石は結晶粒を覆っている形状が観察されなかったが、上記実施例2及び3の磁石は結晶粒の界面にNdリッチ相が存在することが確認された。
上記実施例2及び3の熱間加圧変形磁石に対して、EDSマッピング分析を行い、その結果を図2に示す。図2から、上記実施例2及び3の熱間加圧変形磁石の内部に低融点金属化合物であるNd系化合物又はPr系化合物が含有されていることが確認された。
上記実施例2〜4の熱間加圧変形磁石、並びに上記比較例1及び2の焼結磁石に対して、VSM(vibrating sample magnetometer, Lake Shore #7410 USA)を用いて磁石の性能の尺度である保磁力及び残留磁束密度を評価し、その結果値を下記表1に示す。
Claims (15)
- (i)異方化された板状結晶粒と、
(ii)前記結晶粒の界面に分布した非磁性合金とを含む、R−TM−B(ここで、Rは、Nd、Dy、Pr、Tb、Ho、Sm、Sc、Y、La、Ce、Pm、Eu、Gd、Er、Tm、Yb、Lu及びそれらの組み合わせからなる群から選択される希土類金属であり、TMは、遷移金属を意味する)熱間加圧変形磁石。 - 前記非磁性合金は、Nd0.84Cu0.16、Nd0.7Cu0.3、Nd0.85Al0.15、Nd0.08Al0.92、Nd0.03Sb0.97、Nd0.8Ga0.2、Nd0.769Zn0.231、Nd0.07Mg0.93、Pr0.84Cu0.16、Pr0.7Cu0.3、Pr0.85Al0.15、Pr0.08Al0.92、Pr0.03Sb0.97、Pr0.8Ga0.2、Pr0.769Zn0.231、Pr0.07Mg0.93、Bi、Ga、Ni、Co及びそれらの組み合わせからなる群から選択されるいずれかを含む、請求項1に記載の磁石。
- 前記非磁性合金は、融点が400〜700℃である、請求項1に記載の磁石。
- 前記結晶粒は、その直径が100〜1000nmである、請求項1に記載の磁石。
- (a)R−TM−B(ここで、Rは、Nd、Dy、Pr、Tb、Ho、Sm、Sc、Y、La、Ce、Pm、Eu、Gd、Er、Tm、Yb、Lu及びそれらの組み合わせからなる群から選択される希土類金属であり、TMは、遷移金属を意味する)合金から磁性粉末を作製する段階と、
(b)前記磁性粉末を加圧焼結して焼結体を作製する段階と、
(c)熱と圧力を加えて前記焼結体を熱間加圧変形する段階とを含み、
前記段階(a)におけるR−TM−B合金の作製時又は前記段階(b)における加圧焼結前に、非磁性合金を添加することを含む、R−TM−B熱間加圧変形磁石の製造方法。 - 前記磁性粉末には、HDDR工程、溶融紡糸工程、急速固化工程及びそれらの組み合わせからなる群から選択されるいずれかの工程で作製された磁性粉末が含まれる、請求項7に記載の製造方法。
- 前記非磁性合金は、前記磁性粉末に対して0.01〜10重量%添加される、請求項7に記載の製造方法。
- 前記段階(b)は、300〜800℃の温度で行われる、請求項7に記載の製造方法。
- 前記段階(c)は、500〜1000℃の温度で行われる、請求項7に記載の製造方法。
- 前記非磁性合金は、前記段階(b)における加圧焼結前に添加されて前記磁性粉末と混合される、請求項7に記載の製造方法。
- 前記段階(b)と前記段階(c)との間に、前記焼結体に追加熱処理を行う段階をさらに含む、請求項12に記載の製造方法。
- 前記追加熱処理は、400〜800℃の温度で行われる、請求項13に記載の製造方法。
- 前記段階(c)における熱間加圧変形の変形率は、50〜80%である、請求項7に記載の製造方法。
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US20170330658A1 (en) | 2017-11-16 |
US10950373B2 (en) | 2021-03-16 |
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