JP2021136347A - 希土類磁石の製造方法 - Google Patents
希土類磁石の製造方法 Download PDFInfo
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- JP2021136347A JP2021136347A JP2020031997A JP2020031997A JP2021136347A JP 2021136347 A JP2021136347 A JP 2021136347A JP 2020031997 A JP2020031997 A JP 2020031997A JP 2020031997 A JP2020031997 A JP 2020031997A JP 2021136347 A JP2021136347 A JP 2021136347A
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- Prior art keywords
- powder
- zinc
- nitrogen
- iron
- magnetic powder
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Links
- 229910052761 rare earth metal Inorganic materials 0.000 title claims abstract description 63
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 58
- 150000002910 rare earth metals Chemical class 0.000 title claims abstract description 53
- 239000000843 powder Substances 0.000 claims abstract description 210
- 239000006247 magnetic powder Substances 0.000 claims abstract description 188
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims abstract description 146
- 239000011701 zinc Substances 0.000 claims abstract description 136
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 127
- 239000002245 particle Substances 0.000 claims abstract description 102
- 239000011230 binding agent Substances 0.000 claims abstract description 101
- 239000011248 coating agent Substances 0.000 claims abstract description 74
- 238000000576 coating method Methods 0.000 claims abstract description 74
- 230000008018 melting Effects 0.000 claims abstract description 41
- 238000002844 melting Methods 0.000 claims abstract description 41
- 239000011812 mixed powder Substances 0.000 claims abstract description 35
- 238000002441 X-ray diffraction Methods 0.000 claims abstract description 12
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 66
- 238000000034 method Methods 0.000 claims description 65
- 238000005245 sintering Methods 0.000 claims description 62
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 43
- 229910052757 nitrogen Inorganic materials 0.000 claims description 42
- 229910045601 alloy Inorganic materials 0.000 claims description 14
- 239000000956 alloy Substances 0.000 claims description 14
- 239000013078 crystal Substances 0.000 claims description 14
- 238000000748 compression moulding Methods 0.000 claims description 13
- 229910052751 metal Inorganic materials 0.000 claims description 11
- 239000002184 metal Substances 0.000 claims description 11
- 229910052772 Samarium Inorganic materials 0.000 claims description 10
- KZUNJOHGWZRPMI-UHFFFAOYSA-N samarium atom Chemical compound [Sm] KZUNJOHGWZRPMI-UHFFFAOYSA-N 0.000 claims description 10
- 229910052742 iron Inorganic materials 0.000 claims description 9
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 8
- 229910052797 bismuth Inorganic materials 0.000 claims description 8
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 claims description 8
- 229910000881 Cu alloy Inorganic materials 0.000 claims description 7
- 229910000611 Zinc aluminium Inorganic materials 0.000 claims description 7
- HXFVOUUOTHJFPX-UHFFFAOYSA-N alumane;zinc Chemical compound [AlH3].[Zn] HXFVOUUOTHJFPX-UHFFFAOYSA-N 0.000 claims description 7
- 239000000203 mixture Substances 0.000 claims description 5
- PRQMIVBGRIUJHV-UHFFFAOYSA-N [N].[Fe].[Sm] Chemical compound [N].[Fe].[Sm] PRQMIVBGRIUJHV-UHFFFAOYSA-N 0.000 abstract description 84
- 238000002360 preparation method Methods 0.000 abstract description 16
- 230000005415 magnetization Effects 0.000 abstract description 9
- 239000012071 phase Substances 0.000 description 54
- 239000010408 film Substances 0.000 description 44
- 238000010438 heat treatment Methods 0.000 description 35
- 238000010586 diagram Methods 0.000 description 21
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 18
- 239000001301 oxygen Substances 0.000 description 18
- 229910052760 oxygen Inorganic materials 0.000 description 18
- 229910001297 Zn alloy Inorganic materials 0.000 description 15
- 230000000052 comparative effect Effects 0.000 description 13
- 239000000463 material Substances 0.000 description 12
- 239000012535 impurity Substances 0.000 description 11
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 11
- -1 samarium-iron-nitrogen rare earth Chemical class 0.000 description 11
- 230000000694 effects Effects 0.000 description 10
- 238000002156 mixing Methods 0.000 description 10
- AWWAHRLLQMQIOC-UHFFFAOYSA-N [Fe].[Sm] Chemical compound [Fe].[Sm] AWWAHRLLQMQIOC-UHFFFAOYSA-N 0.000 description 9
- 238000003860 storage Methods 0.000 description 9
- 229910052782 aluminium Inorganic materials 0.000 description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 8
- 238000007796 conventional method Methods 0.000 description 8
- 239000000155 melt Substances 0.000 description 8
- 239000010949 copper Substances 0.000 description 7
- 230000008569 process Effects 0.000 description 7
- 238000003756 stirring Methods 0.000 description 7
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 6
- 239000011261 inert gas Substances 0.000 description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical group [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 5
- 229910052802 copper Inorganic materials 0.000 description 5
- 239000002994 raw material Substances 0.000 description 5
- 229910001873 dinitrogen Inorganic materials 0.000 description 4
- 238000002149 energy-dispersive X-ray emission spectroscopy Methods 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- 239000007791 liquid phase Substances 0.000 description 4
- 238000001000 micrograph Methods 0.000 description 4
- 239000003607 modifier Substances 0.000 description 4
- 230000003647 oxidation Effects 0.000 description 4
- 238000007254 oxidation reaction Methods 0.000 description 4
- 238000007736 thin film deposition technique Methods 0.000 description 4
- 229910000640 Fe alloy Inorganic materials 0.000 description 3
- 229910052786 argon Inorganic materials 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 238000010298 pulverizing process Methods 0.000 description 3
- 238000005211 surface analysis Methods 0.000 description 3
- 229910052771 Terbium Inorganic materials 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000013590 bulk material Substances 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 238000007561 laser diffraction method Methods 0.000 description 2
- 229910001172 neodymium magnet Inorganic materials 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
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- 239000000126 substance Substances 0.000 description 2
- GZCRRIHWUXGPOV-UHFFFAOYSA-N terbium atom Chemical group [Tb] GZCRRIHWUXGPOV-UHFFFAOYSA-N 0.000 description 2
- 229910052718 tin Inorganic materials 0.000 description 2
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 2
- 238000007740 vapor deposition Methods 0.000 description 2
- ZSLUVFAKFWKJRC-IGMARMGPSA-N 232Th Chemical compound [232Th] ZSLUVFAKFWKJRC-IGMARMGPSA-N 0.000 description 1
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 1
- 238000007088 Archimedes method Methods 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910052684 Cerium Inorganic materials 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229910052692 Dysprosium Inorganic materials 0.000 description 1
- 229910052691 Erbium Inorganic materials 0.000 description 1
- 229910052688 Gadolinium Inorganic materials 0.000 description 1
- GYHNNYVSQQEPJS-UHFFFAOYSA-N Gallium Chemical compound [Ga] GYHNNYVSQQEPJS-UHFFFAOYSA-N 0.000 description 1
- 229910052689 Holmium Inorganic materials 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- 229910052777 Praseodymium Inorganic materials 0.000 description 1
- 229910052773 Promethium Inorganic materials 0.000 description 1
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 229910052776 Thorium Inorganic materials 0.000 description 1
- 229910052775 Thulium Inorganic materials 0.000 description 1
- 229910052769 Ytterbium Inorganic materials 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 229910007570 Zn-Al Inorganic materials 0.000 description 1
- QJVKUMXDEUEQLH-UHFFFAOYSA-N [B].[Fe].[Nd] Chemical compound [B].[Fe].[Nd] QJVKUMXDEUEQLH-UHFFFAOYSA-N 0.000 description 1
- 230000009471 action Effects 0.000 description 1
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- 239000011324 bead Substances 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- KPLQYGBQNPPQGA-UHFFFAOYSA-N cobalt samarium Chemical compound [Co].[Sm] KPLQYGBQNPPQGA-UHFFFAOYSA-N 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- KBQHZAAAGSGFKK-UHFFFAOYSA-N dysprosium atom Chemical compound [Dy] KBQHZAAAGSGFKK-UHFFFAOYSA-N 0.000 description 1
- UYAHIZSMUZPPFV-UHFFFAOYSA-N erbium Chemical compound [Er] UYAHIZSMUZPPFV-UHFFFAOYSA-N 0.000 description 1
- 239000006023 eutectic alloy Substances 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- UIWYJDYFSGRHKR-UHFFFAOYSA-N gadolinium atom Chemical compound [Gd] UIWYJDYFSGRHKR-UHFFFAOYSA-N 0.000 description 1
- 229910052733 gallium Inorganic materials 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- KJZYNXUDTRRSPN-UHFFFAOYSA-N holmium atom Chemical compound [Ho] KJZYNXUDTRRSPN-UHFFFAOYSA-N 0.000 description 1
- 150000002431 hydrogen Chemical class 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 229910001026 inconel Inorganic materials 0.000 description 1
- KFZAUHNPPZCSCR-UHFFFAOYSA-N iron zinc Chemical compound [Fe].[Zn] KFZAUHNPPZCSCR-UHFFFAOYSA-N 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 239000000696 magnetic material Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 239000004570 mortar (masonry) Substances 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- 238000005121 nitriding Methods 0.000 description 1
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- VQMWBBYLQSCNPO-UHFFFAOYSA-N promethium atom Chemical compound [Pm] VQMWBBYLQSCNPO-UHFFFAOYSA-N 0.000 description 1
- 238000010926 purge Methods 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 229910052702 rhenium Inorganic materials 0.000 description 1
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 description 1
- 229910052707 ruthenium Inorganic materials 0.000 description 1
- 229940075630 samarium oxide Drugs 0.000 description 1
- 229910001954 samarium oxide Inorganic materials 0.000 description 1
- FKTOIHSPIPYAPE-UHFFFAOYSA-N samarium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[Sm+3].[Sm+3] FKTOIHSPIPYAPE-UHFFFAOYSA-N 0.000 description 1
- 229910000938 samarium–cobalt magnet Inorganic materials 0.000 description 1
- 229910052706 scandium Inorganic materials 0.000 description 1
- SIXSYDAISGFNSX-UHFFFAOYSA-N scandium atom Chemical compound [Sc] SIXSYDAISGFNSX-UHFFFAOYSA-N 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000007790 solid phase Substances 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
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- 238000006467 substitution reaction Methods 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- NAWDYIZEMPQZHO-UHFFFAOYSA-N ytterbium Chemical compound [Yb] NAWDYIZEMPQZHO-UHFFFAOYSA-N 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0483—Alloys based on the low melting point metals Zn, Pb, Sn, Cd, In or Ga
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/17—Metallic particles coated with metal
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0433—Nickel- or cobalt-based alloys
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C18/00—Alloys based on zinc
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0207—Using a mixture of prealloyed powders or a master alloy
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- 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
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/0551—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 in the form of particles, e.g. rapid quenched powders or ribbon flakes
- H01F1/0552—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 in the form of particles, e.g. rapid quenched powders or ribbon flakes with a protective layer
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- 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
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/0555—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 pressed, sintered or bonded together
- H01F1/0557—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 pressed, sintered or bonded together sintered
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- 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
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/0555—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 pressed, sintered or bonded together
- H01F1/0558—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 pressed, sintered or bonded together bonded together
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—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
- 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
- H01F41/0266—Moulding; Pressing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2202/00—Treatment under specific physical conditions
- B22F2202/05—Use of magnetic field
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C2202/00—Physical properties
- C22C2202/02—Magnetic
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- 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
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/059—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and Va elements, e.g. Sm2Fe17N2
- H01F1/0596—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and Va elements, e.g. Sm2Fe17N2 of rhombic or rhombohedral Th2Zn17 structure or hexagonal Th2Ni17 structure
Abstract
Description
〈1〉サマリウム、鉄、及び窒素を含有し、Th2Zn17型及びTh2Ni17型の少なくともいずれかの結晶構造を有する磁性相を備える磁性粉末の粒子の表面に、亜鉛を含有する被膜を形成して、被覆磁性粉末を得ること、
前記被膜の融点以下の融点を有するバインダ粉末及び前記磁性粉末を混合して、混合粉末を得ること、並びに、
前記バインダ粉末のX線回折パターンでピークが消滅する温度をT1℃、前記磁性相が分解する温度をT2℃としたとき、前記混合粉末を、T1℃以上、(T2−50)℃以下で加圧焼結すること、
を含む、希土類磁石の製造方法。
〈2〉前記被覆磁性粉末の粒子の断面で、前記磁性粉末の粒子表面の全周長さに対する、前記被膜が前記磁性粉末の粒子表面を被覆している部分の長さの百分率が90%以上である、〈1〉項に記載の希土類磁石の製造方法。
〈3〉前記バインダ粉末が、亜鉛以外の金属を含有する粉末、及び亜鉛以外の金属の合金を含有する粉末の少なくともいずれかの粉末である、〈1〉項又は〈2〉項に記載の方法。
〈4〉前記バインダ粉末が、金属亜鉛を含有する粉末、亜鉛−アルミニウム系合金を含有する粉末、アルミニウム−ランタン−銅系合金を含有する粉末、金属錫を含有する粉末、及び金属ビスマスを含有する粉末からなる群より選ばれる一種以上の粉末である、〈1〉項又は〈2〉項に記載の方法。
〈5〉前記混合粉末を、前記バインダ粉末の融点以上で加圧焼結する、〈1〉項〜〈4〉項のいずれか一項に記載の方法。
〈6〉前記加圧焼結の前に、前記混合粉末を磁場中で圧縮成形することをさらに含む、〈1〉項〜〈5〉項のいずれか一項に記載の方法。
本開示の希土類磁石の製造方法は、被覆磁性粉末準備工程、混合粉末準備工程、及び加圧焼結工程を含む。以下、各工程について説明する。
サマリウム、鉄、及び窒素を含有し、Th2Zn17型及びTh2Ni17型の少なくともいずれかの結晶構造を有する磁性相を備える磁性粉末の粒子の表面に、亜鉛を含有する被膜を形成して、被覆磁性粉末を得る。亜鉛を含有する被膜とは、金属亜鉛を含有する被膜及び亜鉛合金を含有する被膜の少なくともいずれかを意味する。
図3は、ロータリーキルン炉を用いて、サマリウム−鉄−窒素系磁性粉末の粒子の表面に亜鉛を含有する被膜を形成する方法の一例を示す説明図である。
図4は、サマリウム−鉄−窒素系磁性粉末の粒子の表面に亜鉛を含有する被膜を蒸着法で形成する方法の一例を示す説明図である。
サマリウム−鉄−窒素系磁性粉末の粒子の表面に形成される被膜の被覆百分率は、被覆磁性粉末の粒子を透過型電子顕微鏡(TEM:Transmission electron microscopy)で観察し、被膜部分をエネルギー分散型X線(EDX:Eergy−Dispersive X−ray spectroscopy)で亜鉛を面分析して求める。図5は、被覆磁性粉末をTEM−EDXを用いて亜鉛を面分析した一例を示す画像である。明視野は亜鉛の存在している箇所を示す。
亜鉛を含有する被膜の融点以下の融点を有するバインダ粉末及び被覆磁性粉末を混合して、混合粉末を得る。バインダ粉末の詳細については後述する。
混合粉末を加圧焼結する。加圧焼結の前に混合粉末を圧縮成形して、圧粉体を得た後、圧粉体を加圧焼結してもよい。混合粉末の圧縮成形については後述する。
上述したように、任意で、加圧焼結の前に、混合粉末を圧縮成形して圧粉体を得てもよい。圧縮成形方法に特に制限はない。圧縮成形工程で用いる金型を、加圧焼結工程及び後述する磁場印加工程で用いる金型と共用してもよい。圧縮成形工程で用いる金型を、加圧焼結工程及び磁場印加工で用いる金型と共有する場合には、金型のキャビティ内に磁場を印加し易く、かつ焼結時の高温及び高圧に耐え得る材質で造られていることが好ましい。金型の材質としては、例えば、タングステンカーバイド系超硬合金及び/又はインコネル等が挙げられる。また、これらの組合せであってもよい。金型の耐久性等の観点からは、金型の材質は、タングステンカーバイド系超硬合金であることが好ましい。
混合粉末の圧縮成形時に、混合粉末に磁場を印加してもよい。これにより、焼結体に異方性を付与することができる。磁場の印加方向は特に制限されないが、典型的には、混合粉末の圧縮成形方向と垂直な方向に磁場を印加する。
本開示の希土類磁石の製造方法に用いる磁性粉末は、サマリウム、鉄、及び窒素を含有し、Th2Zn17型及びTh2Ni17型の少なくともいずれかの結晶構造を有する磁性相を含有する。磁性相の結晶構造としては、前述の構造のほかに、TbCu7型の結晶構造を有する相等が挙げられる。なお、Thはトリウム、Znは亜鉛、Niはニッケル、Tbはテルビウム、そして、Cuは銅である。
バインダ粉末は、亜鉛の融点以下の融点を有する。バインダ粉末は、サマリウム−鉄−窒素系磁性粉末と混合され、加圧焼結に供される。このことから、バインダ粉末は、典型的には、金属粉末及び/又は合金粉末である。すなわち、バインダ粉末は、典型的には、亜鉛の融点以下の融点を有する金属粉末及び/又は合金粉末である。
被覆磁性粉末準備工程で亜鉛を含有する粉末を用いる。バインダ粉末として用いる亜鉛を含有する粉末を被覆磁性粉末準備工程でも用いることができる。ただし、セリウム−鉄−窒素系磁性粉末の粒子の表面に形成される被膜は、酸素を吸収して改質に寄与する。亜鉛を含有する粉末の酸素含有量が少ないと、セリウム−鉄−窒素系磁性粉末中の酸素を多く吸収できて好ましい。この観点からは、亜鉛を含有する粉末を被覆磁性粉末準備工程で用いる場合には、その酸素含有量は、亜鉛を含有する粉末全体に対し、5.0質量%以下が好ましく、3.0質量%がより好ましく、1.0質量%以下がより一層好ましい。一方、亜鉛を含有する粉末の酸素の含有量を極度に低減することは、製造コストの増大を招く。このことから、亜鉛を含有する粉末の酸素の含有量は、亜鉛を含有する粉末全体に対して、0.1質量%以上、0.2質量%以上、又は0.3質量%以上であってよい。
希土類磁石の試料を次の要領で準備した。
93.0質量%のSm2Fe17N3を含有するサマリウム−鉄−窒素系磁性粉末の粒子の表面に、金属亜鉛粉末を用いて被覆磁性粉末を準備した。サマリウム−鉄−窒素系磁性粉末の粒度はD50で3.16μmであった。金属亜鉛粉末の粒度はD50で1.0μmであり、金属亜鉛粉末の純度は99.4質量%であった。
サマリウム−鉄−窒素系磁性粉末の粒子の表面に被膜を形成しなかったこと以外、実施例と同様に比較例1の試料を準備した。また、バインダ粉末を混合しなかったこと以外、実施例と同様に比較例2の試料を準備した。
実施例1〜12及び比較例1〜2の試料について、密度と磁気特性を測定した。測定は室温で行った。密度はアルキメデス法で測定した。保磁力は振動試料型磁力計(VSM)を用いて測定し、残留磁化は直流磁化磁束計で測定した。また、実施例1及び比較例1については、試料の表面を研磨し、その表面を、走査型電子顕微鏡(SEM:Scanning Electron Microscope)を用いて観察した。さらに、実施例1〜12及び比較例2については、図5等で示した方法で、被覆磁性粉末の被覆百分率を求めた。
12 被膜
14 被覆磁性粉末
20 バインダ粉末
30 圧粉体
40 亜鉛を含有する粉末
100 ロータリーキルン炉
110 撹拌ドラム
120 材料格納部
130 回転軸
140 攪拌板
171 第1熱処理炉
172 第2熱処理炉
173 連結路
180 真空ポンプ
181 第1容器
182 第2容器
200 ダイス
210 キャビティ
220 パンチ
240 ヒータ
Claims (6)
- サマリウム、鉄、及び窒素を含有し、Th2Zn17型及びTh2Ni17型の少なくともいずれかの結晶構造を有する磁性相を備える磁性粉末の粒子の表面に、亜鉛を含有する被膜を形成して、被覆磁性粉末を得ること、
前記被膜の融点以下の融点を有するバインダ粉末及び前記被覆磁性粉末を混合して、混合粉末を得ること、並びに、
前記バインダ粉末のX線回折パターンでピークが消滅する温度をT1℃、前記磁性相が分解する温度をT2℃としたとき、前記混合粉末を、T1℃以上、(T2−50)℃以下で加圧焼結すること、
を含む、希土類磁石の製造方法。 - 前記被覆磁性粉末の粒子の断面で、前記磁性粉末の粒子表面の全周長さに対する、前記被膜が前記磁性粉末の粒子表面を被覆している部分の長さの百分率が90%以上である、請求項1に記載の希土類磁石の製造方法。
- 前記バインダ粉末が、亜鉛以外の金属を含有する粉末、及び亜鉛以外の金属の合金を含有する粉末の少なくともいずれかの粉末である、請求項1又は2に記載の方法。
- 前記バインダ粉末が、金属亜鉛を含有する粉末、亜鉛−アルミニウム系合金を含有する粉末、アルミニウム−ランタン−銅系合金を含有する粉末、金属錫を含有する粉末、及び金属ビスマスを含有する粉末からなる群より選ばれる一種以上の粉末である、請求項1又は2に記載の方法。
- 前記混合粉末を、前記バインダ粉末の融点以上で加圧焼結する、請求項1〜4のいずれか一項に記載の方法。
- 前記加圧焼結の前に、前記混合粉末を磁場中で圧縮成形することをさらに含む、請求項1〜5のいずれか一項に記載の方法。
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