JP2019203150A - 軟磁性粉末、圧粉体および磁性部品 - Google Patents
軟磁性粉末、圧粉体および磁性部品 Download PDFInfo
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- 239000006247 magnetic powder Substances 0.000 title claims abstract description 119
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 24
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 24
- 239000001301 oxygen Substances 0.000 claims abstract description 24
- 239000000843 powder Substances 0.000 claims abstract description 16
- 229910052735 hafnium Inorganic materials 0.000 claims abstract description 6
- 229910052750 molybdenum Inorganic materials 0.000 claims abstract description 6
- 229910052758 niobium Inorganic materials 0.000 claims abstract description 6
- 229910052715 tantalum Inorganic materials 0.000 claims abstract description 6
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 6
- 229910052721 tungsten Inorganic materials 0.000 claims abstract description 6
- 229910052720 vanadium Inorganic materials 0.000 claims abstract description 6
- 229910052726 zirconium Inorganic materials 0.000 claims abstract description 6
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 5
- 229910052787 antimony Inorganic materials 0.000 claims abstract description 5
- 229910052785 arsenic Inorganic materials 0.000 claims abstract description 5
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 5
- 229910052802 copper Inorganic materials 0.000 claims abstract description 5
- 229910052748 manganese Inorganic materials 0.000 claims abstract description 5
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 5
- 229910052761 rare earth metal Inorganic materials 0.000 claims abstract description 5
- 229910052709 silver Inorganic materials 0.000 claims abstract description 5
- 229910052718 tin Inorganic materials 0.000 claims abstract description 5
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 5
- 239000000203 mixture Substances 0.000 claims description 50
- 239000002245 particle Substances 0.000 claims description 28
- 239000000523 sample Substances 0.000 claims description 18
- 239000002159 nanocrystal Substances 0.000 claims description 16
- 239000013081 microcrystal Substances 0.000 claims description 12
- 238000010438 heat treatment Methods 0.000 description 41
- 230000005415 magnetization Effects 0.000 description 32
- 238000000034 method Methods 0.000 description 24
- 239000013078 crystal Substances 0.000 description 21
- 230000000052 comparative effect Effects 0.000 description 20
- 230000002349 favourable effect Effects 0.000 description 14
- 229910052751 metal Inorganic materials 0.000 description 14
- 239000002184 metal Substances 0.000 description 13
- 238000005259 measurement Methods 0.000 description 11
- 229910045601 alloy Inorganic materials 0.000 description 9
- 239000000956 alloy Substances 0.000 description 9
- 239000012298 atmosphere Substances 0.000 description 8
- 125000004429 atom Chemical group 0.000 description 7
- 238000000465 moulding Methods 0.000 description 6
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- 229910052799 carbon Inorganic materials 0.000 description 5
- 238000010586 diagram Methods 0.000 description 5
- 238000002441 X-ray diffraction Methods 0.000 description 4
- 229910000808 amorphous metal alloy Inorganic materials 0.000 description 4
- 239000011230 binding agent Substances 0.000 description 4
- 230000005540 biological transmission Effects 0.000 description 4
- 230000004907 flux Effects 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- 238000009689 gas atomisation Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 229910052717 sulfur Inorganic materials 0.000 description 4
- 230000003247 decreasing effect Effects 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 238000004458 analytical method Methods 0.000 description 2
- 238000004364 calculation method Methods 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 239000012299 nitrogen atmosphere Substances 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 101000993059 Homo sapiens Hereditary hemochromatosis protein Proteins 0.000 description 1
- 230000008859 change Effects 0.000 description 1
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- 238000002524 electron diffraction data Methods 0.000 description 1
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- 230000006872 improvement Effects 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 229910001004 magnetic alloy Inorganic materials 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
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- 230000009467 reduction Effects 0.000 description 1
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Abstract
Description
組成式(Fe(1−(α+β))X1αX2β)(1−(a+b+c+d+e+f))MaBbPcSidCeSfからなる主成分を含む軟磁性粉末であって、
X1はCoおよびNiからなる群から選択される1種以上、
X2はAl,Mn,Ag,Zn,Sn,As,Sb,Cu,Cr,Bi,N,および希土類元素からなる群より選択される1種以上、
MはNb,Hf,Zr,Ta,Mo,W,TiおよびVからなる群から選択される1種以上であり、
0≦a≦0.140
0.020<b≦0.200
0<c≦0.150
0≦d≦0.060
0≦e≦0.030
0≦f≦0.010
α≧0
β≧0
0≦α+β≦0.50
であり、
前記軟磁性粉末における酸素含有率が質量比で300ppm以上3000ppm以下である。
前記Fe組成ネットワーク相は、局所的にFe含有割合が周囲よりも高くなるFe含有割合の極大点を40万個/μm3以上有していてもよく、
全ての前記Fe含有割合の極大点の中で、配位数が1以上5以下である前記Fe含有割合の極大点の割合が80%以上100%以下であってもよい。
X1はCoおよびNiからなる群から選択される1種以上、
X2はAl,Mn,Ag,Zn,Sn,As,Sb,Cu,Cr,Bi,N,および希土類元素からなる群より選択される1種以上、
MはNb,Hf,Zr,Ta,Mo,W,TiおよびVからなる群から選択される1種以上であり、
0≦a≦0.140
0.020<b≦0.200
0<c≦0.150
0≦d≦0.060
0≦e≦0.030
0≦f≦0.010
α≧0
β≧0
0≦α+β≦0.50
であり、
前記軟磁性粉末における酸素含有率が質量比で300ppm以上3000ppm以下である。
下表に示す各実施例および比較例の合金組成となるように原料金属を秤量し、高周波加熱にて溶解し、母合金を作製した。なお、試料番号1(比較例)の組成は一般的によく知られたアモルファス合金の組成である。
実験例2では、溶融金属の温度および熱処理条件を試料番号5から変化させた実施例を行った。結果を下表に示す。なお、試料番号181は熱処理前も熱処理後も結晶が生成せず、非晶質のみを有する構造となった。試料番号181aは熱処理前は非晶質のみを有する構造であり、熱処理後はFe基ナノ結晶を有する構造となった。試料番号182および182aは熱処理前も熱処理後もナノヘテロ構造であった。試料番号182b、183〜189は全て熱処理前はナノヘテロ構造であり、熱処理後はFe基ナノ結晶を有する構造であった。
実験例3では、各試料について3DAP(3次元アトムプローブ)を用いて、Fe含有割合の極大点の個数、配位数が1以上5以下である極大点の割合、配位数が2以上4以下である極大点の割合および試料全体に対するFe組成ネットワーク相の含有割合について測定した。結果を表14に示す。なお、表14に記載した各実施例は、組成が実験例1の試料番号5と同一であり、アトマイズの噴射条件および熱処理温度を制御することで極大点の個数およびFe組成ネットワーク相の体積割合を主に変化させた実施例である。
10a… 極大点
10b… 隣接グリッド
20a…閾値よりも高いFe含有割合である領域
20b…閾値以下のFe含有割合である領域
Claims (11)
- 組成式(Fe(1−(α+β))X1αX2β)(1−(a+b+c+d+e+f))MaBbPcSidCeSfからなる主成分を含む軟磁性粉末であって、
X1はCoおよびNiからなる群から選択される1種以上、
X2はAl,Mn,Ag,Zn,Sn,As,Sb,Cu,Cr,Bi,N,および希土類元素からなる群より選択される1種以上、
MはNb,Hf,Zr,Ta,Mo,W,TiおよびVからなる群から選択される1種以上であり、
0≦a≦0.140
0.020<b≦0.200
0<c≦0.150
0≦d≦0.060
0≦e≦0.030
0≦f≦0.010
α≧0
β≧0
0≦α+β≦0.50
であり、
前記軟磁性粉末における酸素含有率が質量比で300ppm以上3000ppm以下である軟磁性粉末。 - 非晶質である請求項1に記載の軟磁性粉末。
- 非晶質および微結晶からなり前記微結晶が前記非晶質中に存在するナノヘテロ構造が観察される請求項1に記載の軟磁性粉末。
- 前記微結晶の平均粒子径が0.3〜10nmである請求項3に記載の軟磁性粉末。
- Fe基ナノ結晶からなる構造が観察される請求項1に記載の軟磁性粉末。
- 前記Fe基ナノ結晶の平均粒径が3nm以上50nm以下である請求項5に記載の軟磁性粉末。
- 三次元アトムプローブでFe含有割合が前記軟磁性粉末全体に含まれるFe含有割合よりも高い領域が繋がっているFe組成ネットワーク相が観察され、
前記Fe組成ネットワーク相は、局所的にFe含有割合が周囲よりも高くなるFe含有割合の極大点を40万個/μm3以上有し、
全ての前記Fe含有割合の極大点の中で、配位数が1以上5以下である前記Fe含有割合の極大点の割合が80%以上100%以下である請求項1に記載の軟磁性粉末。 - 前記軟磁性粉末全体に占める前記Fe組成ネットワーク相の体積割合が25vol%以上50vol%以下である請求項7に記載の軟磁性粉末。
- 請求項1〜8のいずれかに記載の軟磁性粉末であって、圧力0.1t/cm2で圧粉された状態における体積抵抗率が0.5kΩ・cm以上500kΩ・cm以下である軟磁性粉末。
- 請求項1〜9のいずれかに記載の軟磁性粉末を含む圧粉体。
- 請求項10に記載の圧粉体を有する磁性部品。
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