JP2020521339A - 希土類ボンド磁性粉末、その作製方法及びボンド磁石 - Google Patents
希土類ボンド磁性粉末、その作製方法及びボンド磁石 Download PDFInfo
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- 229910052761 rare earth metal Inorganic materials 0.000 title claims abstract description 47
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- 239000012792 core layer Substances 0.000 claims abstract description 12
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- DLYUQMMRRRQYAE-UHFFFAOYSA-N tetraphosphorus decaoxide Chemical compound O1P(O2)(=O)OP3(=O)OP1(=O)OP2(=O)O3 DLYUQMMRRRQYAE-UHFFFAOYSA-N 0.000 description 2
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- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
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- 229910052721 tungsten Inorganic materials 0.000 description 1
- 238000009736 wetting 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
- 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
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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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- 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
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Abstract
Description
したがって、従来技術の欠点について、性能がより有益な表面処理プロセスを探求する必要が依然としてある。
当該問題を解決するために、本発明は、以下の解決手段を講じる。
本発明に係る作製方法によれば、前記表面窒化処理では、磁性原料粉末と、窒素含有雰囲気とを反応させる。
当該ステップは、主に窒化鉄層1を形成するためのものであり、当該プロセスでは、好ましくは、窒化処理の雰囲気は窒素であり、他のN2+H2、NH3+H2等の雰囲気は窒化効率を向上できるが、Nd2Fe14Bの主相の分解が不可避であり、最終的な磁性粉末の性能に大きく影響する。本ステップは、磁性原料粉末に特定の分布の窒素を形成し、窒素が磁性粉末の表面層に集中し、磁性粉末の主相であるNd2Fe14Bグリッドにできるだけ少なく侵入して主相を安定にさせることが鍵である。
酸化防止剤を有機溶剤に溶解し、溶液を形成し、当該酸化防止剤は、リン酸又はリン酸塩を含む。水分が磁性原料粉末1及び窒化層2と反応することを回避するように、好ましくは、リン酸が無水リン酸である。好ましくは、リン酸塩がIA族、IIA族、IIIA族金属のリン酸塩から選択されたものである。好ましくは、有機溶剤がアセトン又はアルコールであり、酸化防止剤を十分に溶解させることができるだけでなく、酸化防止剤が十分均一に付着させてから、揮発して、固体を完全的に形成することができる。
当該ステップにおいて、磁性粉末と酸化防止剤とを所定の割合で配合し、酸化防止剤溶液に入れて、好ましくは、撹拌方式で十分に反応させる。これは、磁性粉末と酸化防止剤とを均一に反応させるのに有利である。処理してフィルタリングを行った後、乾燥する。
以下、実施例により、さらに、本発明を具体的に説明する。
割合で表1のNo.1〜No.9の各実施例に挙げられた各種の原料(Nd、NdPr、Fe、Co、B、Zr、Nb)を混合した後、誘導溶解炉に入れて、Arガスの保護下で製錬を行い合金インゴットを得る。
表面窒化処理ステップは省略され、その他のステップは実施例1と同様である。
具体的には、表1を参照されたい。
(1)希土類ボンド磁性粉末成分
希土類ボンド磁性粉末の成分は、焼入れ後、得られた希土類合金粉末が熱処理及び窒化処理を経た成分であり、成分は、原子%で表される。
磁性粉末の性能は、振動サンプル磁力計(VSM)により測定することができる。
ただし、Brは残留磁気であり、単位はkGsである。
Hcjは固有保磁力であり、単位はkOeである。
(BH)mは磁気エネルギー積であり、単位はMGOeである。
まず、窒化後の希土類ボンド磁性粉末を300メッシュスクリーンに通し、50μm未満の細粉を取り出し、細粉を除去した後の希土類ボンド磁性粉末質量W1を量る。
耐腐食性能η=(W1−W2)/W1;
損失が1wt.%未満であるサンプルは、耐腐食性が合格であると認定する。
120℃での1000hの不可逆的な磁束損失により測定される。
Claims (10)
- コア層と酸化防止剤層とを含む多層コアシェル構造の希土類ボンド磁性粉末において、コア層がRFeMBからなり、RがNd及び/又はPrNdであり、MがCo、Nb、Zrのうちの1種又は複数種である希土類ボンド磁性粉末であって、
コア層外部には、窒化鉄層が被覆されていることを特徴とする希土類ボンド磁性粉末。 - 前記RFeMBは、Rの含有量が20〜30wt.%であり、Mの含有量が0〜6wt.%であり、Bの含有量が0.85〜1.05wt.%であり、残量はFeであることを特徴とする請求項1に記載の希土類ボンド磁性粉末。
- 前記窒化鉄層は、鉄窒素化合物からなり、窒化鉄層の厚みは50〜500nmであり、好ましくは、厚みは100〜400nmであり、より好ましくは、厚みは150〜350nmであり、最も好ましくは、厚みは200〜300nmであることを特徴とする請求項1に記載の希土類ボンド磁性粉末。
- 前記酸化防止剤層は、リン酸塩複合物からなり、厚みは10〜200nmであり、好ましくは、厚みは20〜160nmであり、最も好ましくは、厚みは50〜80nmであることを特徴とする請求項1に記載の希土類ボンド磁性粉末。
- 請求項1から4の何れか一項に記載の希土類ボンド磁性粉末を作製する方法であって、
磁性原料粉末に対して表面窒化処理を行って窒化物粉末を得ることと、
酸化防止剤溶液を作製することと、
窒化物粉末を酸化防止剤溶液に浸漬し、乾燥を経て、コアシェル構造のボンド磁性粉末を得ることと、を含み、
前記表面窒化処理では、窒化温度は300〜550℃であり、時間は10〜120minであり、好ましくは、窒化温度は350〜550℃であり、時間は10〜100minであり、より好ましくは、窒化温度は400〜550℃であり、時間は10〜60minであり、最も好ましくは、窒化温度は450〜550℃であり、時間は10〜30minであることを特徴とする方法。 - 前記表面窒化処理は、磁性原料粉末と、窒素含有雰囲気とを反応させることを特徴とする請求項5に記載の方法。
- 前記窒素含有雰囲気は、主に窒素ガスで構成されているが、アンモニアガス及び水素ガスを含まないことを特徴とする請求項6に記載の方法。
- 前記酸化防止剤溶液は、リン酸又はその塩を有機溶剤に溶解した溶液であり、酸化防止剤と、有機溶剤との割合は(0.1〜5)g:100mLであることを特徴とする請求項5に記載の方法。
- 前記乾燥温度は80〜110℃であり、好ましくは、乾燥温度は85〜105℃であり、より好ましくは、乾燥温度は90〜105℃であり、最も好ましくは、乾燥温度は95〜105℃であることを特徴とする請求項5に記載の方法。
- 請求項1〜4に記載の希土類ボンド磁性粉末によって作製され、又は、請求項5〜9に記載の方法で作製されたボンド磁石。
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