JP4224073B2 - 希土類磁石及びその製造方法 - Google Patents
希土類磁石及びその製造方法 Download PDFInfo
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- JP4224073B2 JP4224073B2 JP2006075466A JP2006075466A JP4224073B2 JP 4224073 B2 JP4224073 B2 JP 4224073B2 JP 2006075466 A JP2006075466 A JP 2006075466A JP 2006075466 A JP2006075466 A JP 2006075466A JP 4224073 B2 JP4224073 B2 JP 4224073B2
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- Prior art keywords
- protective layer
- rare earth
- magnet
- magnet body
- inorganic particles
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- 238000000034 method Methods 0.000 claims description 28
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- 229910052742 iron Inorganic materials 0.000 claims description 14
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- 239000007864 aqueous solution Substances 0.000 claims description 10
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- DCKVFVYPWDKYDN-UHFFFAOYSA-L oxygen(2-);titanium(4+);sulfate Chemical compound [O-2].[Ti+4].[O-]S([O-])(=O)=O DCKVFVYPWDKYDN-UHFFFAOYSA-L 0.000 description 1
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- 239000011574 phosphorus Substances 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
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- 239000012286 potassium permanganate Substances 0.000 description 1
- BQFYGYJPBUKISI-UHFFFAOYSA-N potassium;oxido(dioxo)vanadium Chemical compound [K+].[O-][V](=O)=O BQFYGYJPBUKISI-UHFFFAOYSA-N 0.000 description 1
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- KZUNJOHGWZRPMI-UHFFFAOYSA-N samarium atom Chemical compound [Sm] KZUNJOHGWZRPMI-UHFFFAOYSA-N 0.000 description 1
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- CMZUMMUJMWNLFH-UHFFFAOYSA-N sodium metavanadate Chemical compound [Na+].[O-][V](=O)=O CMZUMMUJMWNLFH-UHFFFAOYSA-N 0.000 description 1
- 235000015393 sodium molybdate Nutrition 0.000 description 1
- 239000011684 sodium molybdate Substances 0.000 description 1
- TVXXNOYZHKPKGW-UHFFFAOYSA-N sodium molybdate (anhydrous) Chemical compound [Na+].[Na+].[O-][Mo]([O-])(=O)=O TVXXNOYZHKPKGW-UHFFFAOYSA-N 0.000 description 1
- XMVONEAAOPAGAO-UHFFFAOYSA-N sodium tungstate Chemical compound [Na+].[Na+].[O-][W]([O-])(=O)=O XMVONEAAOPAGAO-UHFFFAOYSA-N 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000001384 succinic acid Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- GZCRRIHWUXGPOV-UHFFFAOYSA-N terbium atom Chemical compound [Tb] GZCRRIHWUXGPOV-UHFFFAOYSA-N 0.000 description 1
- FRNOGLGSGLTDKL-UHFFFAOYSA-N thulium atom Chemical compound [Tm] FRNOGLGSGLTDKL-UHFFFAOYSA-N 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 229910000348 titanium sulfate Inorganic materials 0.000 description 1
- 238000007601 warm air drying Methods 0.000 description 1
- NAWDYIZEMPQZHO-UHFFFAOYSA-N ytterbium Chemical compound [Yb] NAWDYIZEMPQZHO-UHFFFAOYSA-N 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
- 229910000166 zirconium phosphate Inorganic materials 0.000 description 1
- ZXAUZSQITFJWPS-UHFFFAOYSA-J zirconium(4+);disulfate Chemical compound [Zr+4].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O ZXAUZSQITFJWPS-UHFFFAOYSA-J 0.000 description 1
- IPCAPQRVQMIMAN-UHFFFAOYSA-L zirconyl chloride Chemical compound Cl[Zr](Cl)=O IPCAPQRVQMIMAN-UHFFFAOYSA-L 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
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- Powder Metallurgy (AREA)
- Chemical Treatment Of Metals (AREA)
- Hard Magnetic Materials (AREA)
- Manufacturing Cores, Coils, And Magnets (AREA)
Description
[希土類磁石の製造]
まず、粉末冶金法により、組成が27.6Nd−4.9Dy−0.5Co−0.4Al−0.07Cu−1.0B−残部Fe(数字は重量百分率を表す。)である鋳塊を作製し、これを粗粉砕した。その後、不活性ガスによるジェットミル粉砕を行って、平均粒径約3.5μmの微粉末を得た。得られた微粉末を金型内に充填し、磁場中で成形した。次いで、真空中で焼結後、熱処理を施して焼結体を得た。得られた焼結体を20mm×10mm×2mmの寸法に切り出し加工し、磁石素体を得た。次に、得られた磁石素体に対し、2%HNO3水溶液中に2分間浸漬する酸洗浄を行った後、超音波洗浄を行った。
実施例1〜6と同様にして得られた磁石素体をそのまま希土類磁石とした。
まず、実施例1〜6と同様にして磁石素体の作製、酸洗浄及び超音波洗浄を行った。得られた磁石素体に対し、スノーテックスC(無機粒子含有量:20重量%)にメタノールを10重量%加えた処理液をスプレーコーティングした。その後、180℃、20分の熱処理を施して、磁石素体の表面にコロイダルシリカ被膜を備える希土類磁石を得た。
[特性評価]
実施例1〜6及び比較例1〜2の希土類磁石に対し、85℃、85%RH、250時間の高温高湿試験を行い、各希土類磁石の外観を観察した。その結果、実施例1〜6の希土類磁石では錆の発生が見られなかったのに対し、比較例1の希土類磁石では試験開始24時間後に錆が発生し、比較例2の希土類磁石では試験開始250時間後に錆が発生した。
Claims (11)
- 少なくとも希土類元素を含む金属元素を含有する磁石素体と、この磁石素体の表面上に形成された保護層と、を備え、
前記保護層は、無機粒子、及び、当該無機粒子の間に前記磁石素体に含まれる金属元素のうちの少なくとも一種と同じ金属元素の化合物を含み、
前記保護層に含まれる前記金属元素のうちの少なくとも一種は、当該保護層の表面側から前記磁石素体側に向かって濃度が大きくなっており、
前記磁石素体は、前記金属元素として鉄を含み、前記保護層は、前記金属元素の化合物として鉄化合物を含む、
ことを特徴とする希土類磁石。 - 前記磁石素体は、前記金属元素としてアルミニウムを含み、前記保護層は、アルミニウム化合物を含む、ことを特徴とする請求項1記載の希土類磁石。
- 前記保護層は、アルミニウムの濃度が前記磁石素体中のアルミニウムの濃度よりも高い部分を含む、ことを特徴とする請求項2記載の希土類磁石。
- 前記磁石素体は、前記金属元素として銅を含み、前記保護層は、銅又は銅化合物を含む、ことを特徴とする請求項1〜3のいずれか一項に記載の希土類磁石。
- 前記無機粒子は、ケイ素、アルミニウム、チタン、ジルコニウム、鉄及びスズからなる群より選ばれる少なくとも一種の元素、並びに、酸素を含む化合物から構成される、ことを特徴とする請求項1〜4のいずれか一項に記載の希土類磁石。
- 前記無機粒子は、シリカ粒子である、ことを特徴とする請求項1〜5のいずれか一項に記載の希土類磁石。
- 少なくとも希土類元素を含む金属元素を含有する磁石素体の表面に、無機粒子を含み酸性を有する水溶液を接触させて、前記表面上に、前記無機粒子、及び、当該無機粒子の間に前記磁石素体に含まれる金属元素のうちの少なくとも一種と同じ金属元素の化合物を含む保護層を形成する工程を有し、
前記保護層に含まれる前記金属元素のうちの少なくとも一種は、当該保護層の表面側から前記磁石素体側に向かって濃度が大きくなっており、
前記磁石素体は、前記金属元素として鉄を含み、前記保護層は、前記金属元素の化合物として鉄化合物を含む、
ことを特徴とする希土類磁石の製造方法。 - 前記水溶液を接触させた後、該水溶液が付着した状態の前記保護層を洗浄する工程を更に有する、ことを特徴とする請求項7記載の希土類磁石の製造方法。
- 前記無機粒子は、ケイ素、アルミニウム、チタン、ジルコニウム、鉄及びスズからなる群より選ばれる少なくとも一種の元素、並びに、酸素を含む化合物から構成される、ことを特徴とする請求項7又は8記載の希土類磁石の製造方法。
- 前記無機粒子は、シリカ粒子である、ことを特徴とする請求項7〜9のいずれか一項に記載の希土類磁石の製造方法。
- 前記水溶液は、酸化剤を含む、ことを特徴とする請求項7〜10のいずれか一項に記載の希土類磁石の製造方法。
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