JP2019220689A - 重希土類粒界拡散型RE−Fe−B系希土類磁石の製造方法、およびそれにより製造された重希土類粒界拡散型RE−Fe−B系稀土類磁石 - Google Patents
重希土類粒界拡散型RE−Fe−B系希土類磁石の製造方法、およびそれにより製造された重希土類粒界拡散型RE−Fe−B系稀土類磁石 Download PDFInfo
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- 150000002910 rare earth metals Chemical class 0.000 title claims abstract description 157
- 238000005324 grain boundary diffusion Methods 0.000 title claims abstract description 67
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 58
- -1 rare earth hydrogen compounds Chemical class 0.000 claims abstract description 40
- 238000009792 diffusion process Methods 0.000 claims abstract description 37
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- 239000006185 dispersion Substances 0.000 claims description 10
- 229910052739 hydrogen Inorganic materials 0.000 claims description 10
- 238000005554 pickling Methods 0.000 claims description 9
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- 239000004593 Epoxy Substances 0.000 claims description 3
- 229910052796 boron Inorganic materials 0.000 claims description 3
- 229910052742 iron Inorganic materials 0.000 claims description 3
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- 239000012300 argon atmosphere Substances 0.000 description 1
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- KBQHZAAAGSGFKK-UHFFFAOYSA-N dysprosium atom Chemical compound [Dy] KBQHZAAAGSGFKK-UHFFFAOYSA-N 0.000 description 1
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- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
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- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 description 1
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- GZCRRIHWUXGPOV-UHFFFAOYSA-N terbium atom Chemical compound [Tb] GZCRRIHWUXGPOV-UHFFFAOYSA-N 0.000 description 1
- 238000007740 vapor deposition Methods 0.000 description 1
- 238000010792 warming Methods 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
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- 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
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- 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
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- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D6/00—Heat treatment of ferrous alloys
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- C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
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- 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
- H01F1/0575—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 pressed, sintered or bonded together
- H01F1/0577—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 pressed, sintered or bonded together sintered
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- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
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- H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
- H01F41/0293—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets diffusion of rare earth elements, e.g. Tb, Dy or Ho, into permanent magnets
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- 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
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Abstract
Description
[数学式1]
残留応力を除去し、粒界拡散時における保磁力および熱減磁特性を改善するために、熱処理温度および時間、昇温速度変化、繰り返し熱処理などの後熱処理過程を経て拡散速度を制御し、且つ残留応力を除去する技術を開発することで、保磁力および熱減磁特性が改善され、均一な品質を有するようにことができる。
[数学式1]
出発原料として、29重量%のRE、69.5重量%のFe、0.5重量%のCo、および1重量%のBの組成からなる希土類焼結磁石を製造するために、該成分の原料を混合、溶融して合金化し、ストリップキャスティングした後、平均粒径が10μmとなるように通常の方法により磁性粉末を製造した。その後、12.5mm*12.5mm*5mm(磁場方向)のサイズの焼結体ブロックとなるように、製造された粉末をモールドに投入した後、200MPaで加圧し、それを真空雰囲気で、1000℃で3時間焼結することで、磁石を製造した。
2次熱処理を行わないか、2次熱処理時における冷却速度を変えたことを除き、実施例1と同様に行って、下記表1のような磁石を製造した。
第1次〜第3次熱処理工程を行わなかったことを除き、実施例1と同様に行って磁石を製造した。
実施例1〜3および比較例1に対して、下記の物性を評価し、下記表1に示した。
試験片の25℃での残留磁束密度、保磁力物性を評価した。
先ず、試験片の外観を光学顕微鏡で観察し、試験片にクラックが発生したか否かを評価し、その結果、試験片にクラックが発生した場合、×と示した。その後、試験片を6等分し、その断面を観察した。総10個の内部断面を光学顕微鏡で観察し、クラックが発生していない場合に0、10個の断面のうち、クラックが発生した断面がある場合には、その断面の個数を1〜10と評価して示した。
Dy−H化合物とDy−F化合物の含量を下記表2のように変えたことを除き、実施例1と同様に行って、下記表2のような磁石を製造した。
Dy−H化合物なしに、Dy−F化合物のみを使用したことを除き、実施例1と同様に行って、下記表2のような磁石を製造した。
実施例5〜7および比較例2に対して、実験例1と同様に行って、下記の物性を評価し、下記表2に示した。
第1重希土類化合物を含有する塗布物質で処理される焼結体として、下記表3のような平均粒径および分散係数を有する磁性粉末を用いて、同様の方法により、同一のサイズの焼結体ブロックを製造し、それを用いて、実施例1と同様の方法により下記表3のような磁石を製造した。
実施例8〜13で準備された試験片に対して、実験例1と同様に評価し、その結果を下記表3に示した。
第1重希土類化合物スラリーである塗布物質の代りに、12重量%のTb−H化合物(TbH2)と88重量%のTb−F化合物(TbF3)の混合物とエタノールとの割合を50%:50%に調節して均一に混練することで、第2重希土類化合物スラリーを製造した。その後、製造されたスラリーをビーカーに入れ、超音波洗浄器を用いて均一に分散させて塗布物質を製造し、製造された塗布物質を用いて、実施例1と同様の方法により下記表4のような磁石を製造した。
2次熱処理を行わないか、2次熱処理時における冷却速度を変えたことを除き、実施例14と同様に行って、下記表4のような磁石を製造した。
第1次〜第3次熱処理工程を行わなかったことを除き、実施例14と同様に行って磁石を製造した。
実施例14〜17および比較例3に対して、実験例1と同様に行って下記の物性を評価し、下記表4に示した。
Tb−H化合物とTb−F化合物の含量を下記表5のように変えたことを除き、実施例14と同様に行って、下記表5のような磁石を製造した。
Dy−H化合物なしに、Dy−F化合物のみを使用したことを除き、実施例1と同様に行って、下記表5のような磁石を製造した。
実施例18〜20および比較例4に対して、実験例1と同様に行って、下記の物性を評価し、下記表5に示した。
Claims (10)
- RE−Fe−TM−B(ここで、RE=稀土類元素、Fe=鉄、TM=3d遷移金属、B=ホウ素)の組成の稀土類磁石焼結体を 磁石製品の規格に応じて加工し、脱脂、酸洗、および溶媒洗浄を経て加工された焼結体を洗浄するステップS1と、
前記ステップS1の洗浄された焼結体の表面に、重希土類水素化合物としてDy−HおよびTb−H化合物の何れか1つ以上を含有する塗布物質を塗布するステップS2と、
前記ステップS2の塗布された焼結体を加熱炉に装入し、重希土類を真空または不活性気体雰囲気で600〜1000℃の範囲で拡散させることで粒界拡散させるステップS3と、
を含む、重希土類粒界拡散型RE−Fe−B系希土類磁石の製造方法。 - 前記ステップS3は、拡散後に900〜1,000℃の範囲で1次熱処理し、600℃以上800℃未満の温度で2次熱処理した後、さらに450℃以上600℃未満の温度で3次熱処理することをさらに含むことを特徴とする請求項1に記載の重希土類粒界拡散型RE−Fe−B系希土類磁石の製造方法。
- 前記ステップS3の拡散物を、金属、エポキシまたは樹脂系で表面処理するステップS4をさらに含むことを特徴とする請求項1に記載の重希土類粒界拡散型RE−Fe−B系希土類磁石の製造方法。
- 前記稀土類磁石焼結体は、RE27〜36重量%、Fe64〜73重量%、TM0〜5重量%、およびB0超過〜2重量%の組成を有することを特徴とする請求項1に記載の重希土類粒界拡散型RE−Fe−B系希土類磁石の製造方法。
- 前記ステップS1の洗浄過程は、加工、脱脂、酸洗、溶媒洗浄の少なくとも1つ以上の工程を経るように構成されることを特徴とする請求項1に記載の重希土類粒界拡散型RE−Fe−B系希土類磁石の製造方法。
- 前記ステップS2の塗布物質は、少なくとも10重量%のDy−H化合物と、残部のDy−F化合物と、を混合した第1重希土類化合物であるか、少なくとも10重量のTb−H化合物と、残部のTb−F化合物と、を混合した第2重希土類化合物であることを特徴とする請求項1に記載の重希土類粒界拡散型RE−Fe−B系希土類磁石の製造方法。
- 前記ステップS3の拡散は、0.1〜20℃/minの昇温速度で昇温し、0.5〜50時間の範囲で維持して拡散反応を行うことを特徴とする請求項1に記載の重希土類粒界拡散型RE−Fe−B系希土類磁石の製造方法。
- 前記ステップS1の焼結体は、平均粒径が20〜35μmの粉末であり、下記の数学式1による磁性粉末の粒径に対する分散係数が25〜40%である磁性粉末を用いて製造されることを特徴とする請求項1に記載の重希土類粒界拡散型RE−Fe−B系希土類磁石の製造方法。
[数学式1]
- 前記ステップS2の塗布物質は、少なくとも10重量%のDy−H化合物と、残部のDy−F化合物とを混合した第1重希土類化合物と、少なくとも10重量%のTb−H化合物と、残部のTb−F化合物とを混合した第2重希土類化合物と、を1:0.4〜0.6の重量比で混合した混合物であることを特徴とする請求項1に記載の重希土類粒界拡散型RE−Fe−B系希土類磁石の製造方法。
- 前記2次熱処理は、1次熱処理後90〜100℃/minの冷却速度で冷却した後、2次熱処理温度で熱処理を行うことを特徴とする請求項2に記載の重希土類粒界拡散型RE−Fe−B系希土類磁石の製造方法。
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