JP4179973B2 - 焼結磁石の製造方法 - Google Patents
焼結磁石の製造方法 Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims description 13
- 229910045601 alloy Inorganic materials 0.000 claims description 40
- 239000000956 alloy Substances 0.000 claims description 40
- 239000002994 raw material Substances 0.000 claims description 25
- 238000000034 method Methods 0.000 claims description 23
- 239000001301 oxygen Substances 0.000 claims description 20
- 229910052760 oxygen Inorganic materials 0.000 claims description 20
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 19
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 16
- 238000005266 casting Methods 0.000 claims description 12
- 229910052751 metal Inorganic materials 0.000 claims description 9
- 239000002184 metal Substances 0.000 claims description 9
- 239000000843 powder Substances 0.000 claims description 9
- 238000005245 sintering Methods 0.000 claims description 9
- 239000007789 gas Substances 0.000 claims description 8
- 229910052796 boron Inorganic materials 0.000 claims description 7
- 230000001590 oxidative effect Effects 0.000 claims description 7
- 239000002245 particle Substances 0.000 claims description 7
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 6
- 229910052742 iron Inorganic materials 0.000 claims description 6
- 238000000465 moulding Methods 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 4
- 229910052723 transition metal Inorganic materials 0.000 claims description 3
- 239000000463 material Substances 0.000 claims 2
- 229910000542 Sc alloy Inorganic materials 0.000 description 21
- 239000000203 mixture Substances 0.000 description 21
- 239000001257 hydrogen Substances 0.000 description 15
- 229910052739 hydrogen Inorganic materials 0.000 description 15
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 14
- 150000002910 rare earth metals Chemical class 0.000 description 9
- 230000007423 decrease Effects 0.000 description 7
- 238000010298 pulverizing process Methods 0.000 description 7
- 238000003860 storage Methods 0.000 description 5
- 230000032683 aging Effects 0.000 description 4
- 238000006356 dehydrogenation reaction Methods 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 3
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- 238000005554 pickling Methods 0.000 description 3
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- 238000005406 washing Methods 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 229910017827 Cu—Fe Inorganic materials 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 2
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- 230000006866 deterioration Effects 0.000 description 2
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- 230000008018 melting Effects 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229910052684 Cerium Inorganic materials 0.000 description 1
- 229910052692 Dysprosium Inorganic materials 0.000 description 1
- 229910052691 Erbium Inorganic materials 0.000 description 1
- 229910052693 Europium Inorganic materials 0.000 description 1
- 229910052688 Gadolinium Inorganic materials 0.000 description 1
- 229910052689 Holmium Inorganic materials 0.000 description 1
- 229910052765 Lutetium Inorganic materials 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
- 229910052777 Praseodymium Inorganic materials 0.000 description 1
- 229910052772 Samarium Inorganic materials 0.000 description 1
- 229910052771 Terbium Inorganic materials 0.000 description 1
- 229910052769 Ytterbium Inorganic materials 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- 239000002671 adjuvant Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 229910052797 bismuth Inorganic materials 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000005238 degreasing Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 229910052733 gallium Inorganic materials 0.000 description 1
- 150000002431 hydrogen Chemical class 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
- 229910000765 intermetallic Inorganic materials 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 230000005389 magnetism Effects 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- 229910017604 nitric acid Inorganic materials 0.000 description 1
- 150000002926 oxygen Chemical class 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
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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
- H01F1/057—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
-
- 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
- C22C1/0441—Alloys based on intermetallic compounds of the type rare earth - Co, Ni
-
- 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
- H01F41/0273—Imparting anisotropy
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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
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
- B22F2009/041—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling by mechanical alloying, e.g. blending, milling
-
- 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
-
- 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
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
-
- 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
- H01F1/057—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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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24917—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including metal layer
Description
本発明は、このような技術的課題に基づいてなされたもので、焼結性の劣化を抑制することのできる焼結磁石の製造方法を提供することを目的とする。
異色付着物1はSC合金に不可避的に発生している。しかるに、異色付着物1の量を規制することにより、そうでない場合に比べて焼結性を向上できることを本発明者等は確認した。特に、この効果は低R組成である場合に顕著となる。
焼結性の低下は、低R組成の場合に顕著となることから、本発明は焼結磁石に含まれるRが27.0〜31.0wt%の範囲にある低R組成の焼結磁石に特に有効である。
本発明の希土類磁石用原料合金は、ストリップキャスト法により得られる。ストリップキャスト法は、原料金属をArガス雰囲気などの非酸化雰囲気中で溶解して得た溶湯を回転するロールの表面に噴出させる。ロールで急冷された溶湯は、薄板または薄片(鱗片)状に急冷凝固される。この急冷凝固された合金は、結晶粒径が1〜50μmの均質な組織を有している。また、急冷凝固された合金は、後の粉砕粉末の粒度分布をシャープにし磁気特性を向上させるために、厚さが0.05〜3mm、Rリッチ相が5μm以下に微細分散した金属組織とすることが望ましい。
SC合金の自由面には、異色付着物以外に、図1に示される微小突起2が形成される。この微小突起2はその内部に酸化物を含んでいるために焼結性を低下させる要因になっているものと推測され、したがってこの微小突起2の生成を抑制することも望まれる。本発明者等の検討によると、異色付着物1の発生を抑制するべく合金溶湯を保持する環境の酸素分圧を低くすることによりこの微小突起2の発生を低減させることができる。
異色付着物1の面積率を低減するには、上述した合金溶湯保持雰囲気の酸素分圧を低くする方法以外に、事後的に異色付着物1を機械的に除去してもよい。また、異色付着物1が生成している部分を取り除いて原料合金とすることもできる。通常、SC合金は、運搬上の都合により、数mmから数cm程度まで粉砕されるが、その中から異色付着物1の存在するSC合金を選別することができる。選別は目視によって行うこともできるが、異色付着物1が0.1〜0.4μm程度の厚さを有していることから、厚さを基準として選別することもできる。
さらに、保磁力を改善するために、Mを加えてR−T−B−M系の希土類永久磁石とすることもできる。ここで、Mとしては、Al、Cr、Mn、Mg、Si、Cu、C、Nb、Sn、W、V、Zr、Ti、Mo、Bi、Ag及びGaなどの元素を1種又は2種以上添加することができる。
以上は、希土類焼結磁石を単一組成の原料合金を用いて製造する場合について説明したが、本発明は異なる組成を有する2種以上の原料合金を用いて希土類焼結磁石を製造する場合に適用することもできる。
本発明による希土類磁石用原料合金は、粉砕し難い金属間化合物(R2Fe14B)を含むため、水素吸蔵処理を施して粉砕を容易にすることが望ましい。
水素吸蔵は、原料合金を常温下で水素含有雰囲気に曝すことにより行うことができる。水素吸蔵反応は発熱反応であるため、温度上昇に伴って吸蔵水素量が低下することを防止するために、反応容器を冷却する等の手段を適用してもよい。水素吸蔵された原料合金は、例えば粒界に沿って亀裂が生じる。
次に、得られた微粉末は磁場中成形に供される。この磁場中成形は、12〜20kOe(960〜1600kA/m)前後の磁場中で、0.3〜3.0t/cm2(30〜300MPa)前後の圧力で行えばよい。
27.55wt%Nd−1.02wt%B−0.04wt%Cu−FeのSC合金を作製した。なお、この組成は、磁気特性の向上を目指した低R組成に該当する。SC合金作製時に、合金溶湯を保持する雰囲気の酸素分圧を種々変化させて5種類のSC合金を得た。また、得られたSC合金の厚さは約320μmであった。5種類のSC合金について、異色付着物の面積率を測定した。その結果を表1に示すが、前述した酸素分圧が高いほど異色付着物の面積率が大きいことが確認された。なお、面積率は、SC合金の自由面のうちでA4サイズ程度の面積を観察することにより算出した。
表1には、焼結体の酸素量(n=4の平均)の測定結果も示しているが、焼結体密度が高いほど酸素量が低い値を示していることから、異色付着物の量が少ないために酸素量が低減して焼結密度が向上したものと解される。
Claims (3)
- R(Rは希土類元素の1種又は2種以上)、T(TはFe又はFe及びCoを必須とする1種又は2種以上の遷移金属元素)及びB(ホウ素)を主成分とし、Rが27.0〜31.0wt%の範囲で含有される焼結磁石の製造方法であって、
ストリップキャスト法により作製された原料合金であって、前記原料合金から異色付着物を機械的に除去するか、又は前記異色付着物の存在する前記原料合金を選別することにより、その表面における前記異色付着物の面積率が1.5%以下にされた前記原料合金を、酸素量が100ppm以下の非酸化性ガスにて気流粉砕して所定粒度の微粉末を作製し、
前記微粉末を磁場中で加圧成形して成形体を作製し、
前記成形体を焼結することを特徴とする焼結磁石の製造方法。 - 前記原料合金は、酸素分圧が0.50Pa以下に制御された雰囲気で溶湯を保持しつつストリップキャスト法により作製されたものであることを特徴とする請求項1に記載の焼結磁石の製造方法。
- 前記異色付着物は、ストリップキャスト法に用いられる冷却ロールとの非接触面に存在することを特徴とする請求項1又は2に記載の焼結磁石の製造方法。
Priority Applications (4)
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JP2003387672A JP4179973B2 (ja) | 2003-11-18 | 2003-11-18 | 焼結磁石の製造方法 |
US10/990,333 US7955442B2 (en) | 2003-11-18 | 2004-11-16 | Method for producing sintered magnet and alloy for sintered magnet |
CNB2004100947629A CN1320565C (zh) | 2003-11-18 | 2004-11-18 | 烧结磁体的制作方法以及烧结磁体用合金 |
US13/103,869 US20110274898A1 (en) | 2003-11-18 | 2011-05-09 | Method for Producing Sintered Magnet and alloy for sintered magnet |
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JP2003387672A JP4179973B2 (ja) | 2003-11-18 | 2003-11-18 | 焼結磁石の製造方法 |
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JP4179973B2 true JP4179973B2 (ja) | 2008-11-12 |
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JP4665419B2 (ja) * | 2004-03-30 | 2011-04-06 | カシオ計算機株式会社 | 画素回路基板の検査方法及び検査装置 |
JP4415980B2 (ja) * | 2006-08-30 | 2010-02-17 | 株式会社日立製作所 | 高抵抗磁石およびそれを用いたモータ |
JP2009231391A (ja) * | 2008-03-19 | 2009-10-08 | Hitachi Metals Ltd | R−t−b系焼結磁石 |
JP5572673B2 (ja) * | 2011-07-08 | 2014-08-13 | 昭和電工株式会社 | R−t−b系希土類焼結磁石用合金、r−t−b系希土類焼結磁石用合金の製造方法、r−t−b系希土類焼結磁石用合金材料、r−t−b系希土類焼結磁石、r−t−b系希土類焼結磁石の製造方法およびモーター |
JP5758016B2 (ja) * | 2012-02-02 | 2015-08-05 | 中央電気工業株式会社 | R−T−B−Ga系磁石用原料合金およびその製造方法 |
US10497497B2 (en) | 2012-02-02 | 2019-12-03 | Santoku Corporation | R-T-B—Ga-based magnet material alloy and method of producing the same |
JP5706841B2 (ja) * | 2012-03-08 | 2015-04-22 | 中央電気工業株式会社 | 合金片の製造方法および合金片の選別装置 |
US9543063B2 (en) * | 2012-11-08 | 2017-01-10 | Shenyang General Magnetic Co., Ltd | Continuous hydrogen pulverization method and production device of rare earth permanent magnetic alloy |
CN103377820B (zh) | 2013-07-17 | 2015-11-25 | 烟台首钢磁性材料股份有限公司 | 一种r-t-b-m系烧结磁体及其制造方法 |
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CN1320565C (zh) | 2007-06-06 |
US20050183791A1 (en) | 2005-08-25 |
US20110274898A1 (en) | 2011-11-10 |
JP2005150503A (ja) | 2005-06-09 |
US7955442B2 (en) | 2011-06-07 |
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