JP5400256B1 - NdFeB系焼結磁石 - Google Patents
NdFeB系焼結磁石 Download PDFInfo
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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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- 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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- H01F41/0293—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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Abstract
Description
プレス有り磁石製造方法では、圧縮成形体を作製するために大型のプレス機が必要となるため、密閉空間内で行うことが難しいのに対し、プレスなし磁石製造工程ではプレス機を用いないことから、密閉空間内で充填から焼結までの作業を行うことができるという特長がある。
また、磁石全体の粒界にRHを行き渡らせることができず、保磁力及び角型比を十分に高めることができなくなる。
NdFeB系合金の粉末を配向し、焼結することにより製造した基材の表面に付着させたDy及び/又はTb(RH)を、粒界拡散処理によって該基材内部の粒界に拡散させたNdFeB系焼結磁石であって、
粒界三重点におけるRHの濃度Ct(wt%)と、二粒子粒界部におけるRHの濃度Cw(wt%)の差Ct-Cwが4wt%以下となる粒界三重点の数が、粒界三重点の総数の60%以上、
であることを特徴とする。
前記基材中の粒界三重点における希土類リッチ相の体積の総計に対する、該希土類リッチ相中の炭素リッチ相の体積の総計の比率が50%以下、
であることが望ましい。このような基材を用いることにより、粒界拡散処理の際にRHが炭素リッチ相に堰き止められることなく、上記のようにRHが粒界中を均等に拡散した構造を得ることができる。
なお、ステップA3〜A5の工程はプレスなし工程により行われる。また、ステップA1〜A5の工程は、一貫して無酸素雰囲気下で行われる。
なお、昇温配向とは、配向工程の際に合金粉末を加熱することにより、合金粉末の各粒子の保磁力を低下させ、配向後の粒子間の反発を抑える方法のことである。この方法により、製造後のNdFeB系焼結磁石の配向度を向上させることができる。
一方、本実施例のNdFeB系焼結磁石の製造方法では脱水素加熱を行わない。そのため、図3に示すように、発熱に伴う温度上昇後、真空脱気しつつ室温まで冷却させる時間を多少長めに取っても、約400分で水素解砕工程を終了することができる。従って、図4の例と比べると、約1000分(16.7時間)ほど製造時間を短縮することができる。
なお、表2の結果は、いずれも微粉砕後の合金粉末の粒径が、レーザ回折法のD50で2.82μmになるように調整した場合のものである。また、微粉砕工程に用いるジェットミル装置には、ホソカワミクロン製100AFG型ジェットミル装置を用いた。磁気特性の測定には、日本電磁測器株式会社製のパルス磁化測定装置(商品名:パルスBHカーブトレーサPBH-1000)を用いた。
また、表2の脱水素無し、昇温配向無しの結果が、本実施例のNdFeB系焼結磁石の製造方法を、脱水素有り、昇温配向有りの結果が、比較例のNdFeB系焼結磁石の製造方法を、それぞれ示している。
さらに、被測定物の表面をイオンスパッタ(例えばArイオンによるスパッタ)していくことで、被測定物の深さ方向の元素分布を調べることができる。
本実施例のNdFeB系焼結磁石では、殆どの小領域において、20%以下の低いC/Ndが得られた。一部の小領域で50%のC/Ndを示す分布が見られたが、50%を超えるC/Ndを示す小領域はなかった。また、領域全体(全ての小領域を合わせた領域)でのC/Ndは26.5%であった。
一方、比較例のNdFeB系焼結磁石では、ほぼ全ての小領域で90%以上という高いC/Ndが得られた。また、領域全体のC/Ndは93.1%であった。
表3の実施例1〜4は、上記(i)〜(iii)の特徴を有する、それぞれ組成番号1〜4の合金に対して本実施例の製造方法により製造した、厚さ方向が磁化方向である縦7mm×横7mm×厚さ3mmのNdFeB系焼結磁石である。また、表3の比較例1〜4は、上記(ii)及び(iii)の特徴を有さない、それぞれ組成番号1〜4の合金から比較例の製造方法により製造した実施例1〜4と同じ大きさのNdFeB系焼結磁石である。これら実施例1〜4及び比較例1〜4のNdFeB系焼結磁石は、後述する粒界拡散法の基材として使用される。
まず、Tb:92wt%、Ni:4.3wt%、Al:3.7wt%のTbNiAl合金粉末とシリコーングリースを重量比で80:20の割合で混合した混合物10gにシリコーンオイルを0.07g添加したペーストを基材の両磁極面(7mm×7mmの面)にそれぞれ10mgずつ塗布した。
次に、上記ペーストを塗布した直方体基材を、複数の尖形状の支持部が設けられたモリブデン製のトレイに載せ、直方体基材を該支持部によって支持しつつ、10-4Paの真空中で加熱した。加熱温度と加熱時間はそれぞれ880℃、10時間とした。その後室温付近まで急冷して、次に500℃で2時間加熱して、再度室温まで急冷した。
これらの数値を比較すると、実施例2のNdFeB系焼結磁石では、同じ出発合金から製造される比較例2のNdFeB系焼結磁石よりも粒界拡散処理後の最大エネルギー積の低下が大きくなっている。しかしながら、それ以外では、本実施例のNdFeB系焼結磁石の方が、同じ組成の出発合金から製造される比較例のNdFeB系焼結磁石よりも最大エネルギー積の低下が抑えられていると共に、その低下量は、比較例の低下量の半分近くになっている。
このように、同じ組成の出発合金に対しては、多くの場合、本実施例のNdFeB系焼結磁石の方が、比較例のNdFeB系焼結磁石よりも、粒界拡散処理後の最大エネルギー積(BH)maxの低下が抑えられる。
11…Ndリッチ相の存在する領域
12…Cが分布する領域
Claims (4)
- NdFeB系合金の粉末を配向し、焼結することにより製造した基材の表面に付着させたDy及び/又はTb(以下、「Dy及び/又はTb」を「RH」とする)を、粒界拡散処理によって該基材内部の粒界に拡散させたNdFeB系焼結磁石であって、
粒界三重点におけるRHの濃度Ct(wt%)と、二粒子粒界部におけるRHの濃度Cw(wt%)の差Ct-Cwが4wt%以下となる粒界三重点の数が、粒界三重点の総数の60%以上、
であることを特徴とするNdFeB系焼結磁石。 - 前記基材中の粒界三重点における希土類リッチ相の体積の総計に対する、該希土類リッチ相中の炭素リッチ相の体積の総計の比率が50%以下、
であることを特徴とする請求項1に記載のNdFeB系焼結磁石。 - 前記基材全体の炭素含有率が1000ppm以下であることを特徴とする請求項1又は2に記載のNdFeB系焼結磁石。
- 前記基材を構成する粒子である主相粒子の平均粒径が4.5μm以下であることを特徴とする請求項1〜3のいずれかに記載のNdFeB系焼結磁石。
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KR (1) | KR101369108B1 (ja) |
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US9837207B2 (en) | 2012-07-24 | 2017-12-05 | Intermetallics Co., Ltd. | Method for producing NdFeB system sintered magnet |
JP6784484B2 (ja) | 2015-09-11 | 2020-11-11 | Tdk株式会社 | R−t−b系焼結磁石およびモータ |
US11328845B2 (en) | 2017-06-27 | 2022-05-10 | Daido Steel Co., Ltd. | RFeB-based magnet and method for producing RFeB-based magnet |
US11527340B2 (en) | 2018-07-09 | 2022-12-13 | Daido Steel Co., Ltd. | RFeB-based sintered magnet |
US20240048911A1 (en) * | 2022-08-05 | 2024-02-08 | Bose Corporation | Grain boundary diffusion for high coercivity magnets for loudspeakers |
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US9396851B2 (en) | 2016-07-19 |
KR101369108B1 (ko) | 2014-03-03 |
US20140118098A1 (en) | 2014-05-01 |
KR20130103642A (ko) | 2013-09-23 |
JPWO2013100009A1 (ja) | 2015-05-11 |
EP2693450A4 (en) | 2014-07-30 |
WO2013100009A1 (ja) | 2013-07-04 |
EP2693450B1 (en) | 2017-03-22 |
EP2693450A1 (en) | 2014-02-05 |
CN103503087B (zh) | 2016-01-20 |
CN103503087A (zh) | 2014-01-08 |
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