JP6052419B2 - 圧粉磁芯用鉄粉および圧粉磁芯用鉄粉の選別方法 - Google Patents
圧粉磁芯用鉄粉および圧粉磁芯用鉄粉の選別方法 Download PDFInfo
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- JP6052419B2 JP6052419B2 JP2015533372A JP2015533372A JP6052419B2 JP 6052419 B2 JP6052419 B2 JP 6052419B2 JP 2015533372 A JP2015533372 A JP 2015533372A JP 2015533372 A JP2015533372 A JP 2015533372A JP 6052419 B2 JP6052419 B2 JP 6052419B2
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 title claims description 290
- 239000000428 dust Substances 0.000 title claims description 71
- 238000000034 method Methods 0.000 title claims description 38
- 239000002245 particle Substances 0.000 claims description 69
- 229910052742 iron Inorganic materials 0.000 claims description 67
- 238000000465 moulding Methods 0.000 claims description 40
- 239000013078 crystal Substances 0.000 claims description 36
- 238000005259 measurement Methods 0.000 claims description 31
- 239000011247 coating layer Substances 0.000 claims description 20
- 238000004458 analytical method Methods 0.000 claims description 15
- 239000010410 layer Substances 0.000 claims description 12
- 229910052804 chromium Inorganic materials 0.000 claims description 11
- 229910052748 manganese Inorganic materials 0.000 claims description 11
- 229910052710 silicon Inorganic materials 0.000 claims description 11
- 229910052782 aluminium Inorganic materials 0.000 claims description 10
- 239000012535 impurity Substances 0.000 claims description 10
- 238000010894 electron beam technology Methods 0.000 claims description 8
- 239000004447 silicone coating Substances 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 5
- 239000000843 powder Substances 0.000 description 98
- 238000000137 annealing Methods 0.000 description 29
- 238000001887 electron backscatter diffraction Methods 0.000 description 25
- 229920005989 resin Polymers 0.000 description 25
- 239000011347 resin Substances 0.000 description 25
- 238000011282 treatment Methods 0.000 description 25
- 239000011248 coating agent Substances 0.000 description 16
- 238000000576 coating method Methods 0.000 description 16
- 229910052751 metal Inorganic materials 0.000 description 15
- 238000010438 heat treatment Methods 0.000 description 14
- 229910000831 Steel Inorganic materials 0.000 description 13
- 239000010959 steel Substances 0.000 description 13
- 239000012298 atmosphere Substances 0.000 description 12
- 238000005261 decarburization Methods 0.000 description 12
- 239000002184 metal Substances 0.000 description 12
- 230000008569 process Effects 0.000 description 12
- 230000009467 reduction Effects 0.000 description 12
- 238000004519 manufacturing process Methods 0.000 description 11
- 239000002994 raw material Substances 0.000 description 10
- 238000009413 insulation Methods 0.000 description 9
- 238000012545 processing Methods 0.000 description 9
- 239000000243 solution Substances 0.000 description 9
- 239000011777 magnesium Substances 0.000 description 8
- 230000002093 peripheral effect Effects 0.000 description 8
- 229920001296 polysiloxane Polymers 0.000 description 8
- 238000009826 distribution Methods 0.000 description 7
- 229910052739 hydrogen Inorganic materials 0.000 description 7
- 239000001257 hydrogen Substances 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 6
- 238000010030 laminating Methods 0.000 description 6
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 5
- 229910052799 carbon Inorganic materials 0.000 description 5
- 239000007787 solid Substances 0.000 description 5
- 238000012360 testing method Methods 0.000 description 5
- 230000004907 flux Effects 0.000 description 4
- 238000005461 lubrication Methods 0.000 description 4
- 239000006249 magnetic particle Substances 0.000 description 4
- 239000011812 mixed powder Substances 0.000 description 4
- 229920005992 thermoplastic resin Polymers 0.000 description 4
- 230000000007 visual effect Effects 0.000 description 4
- 238000009825 accumulation Methods 0.000 description 3
- 238000000889 atomisation Methods 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 238000000748 compression moulding Methods 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000010419 fine particle Substances 0.000 description 3
- 238000007542 hardness measurement Methods 0.000 description 3
- 229910052757 nitrogen Inorganic materials 0.000 description 3
- 238000005498 polishing Methods 0.000 description 3
- 238000001953 recrystallisation Methods 0.000 description 3
- 238000010008 shearing Methods 0.000 description 3
- 238000009692 water atomization Methods 0.000 description 3
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- 229910004298 SiO 2 Inorganic materials 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical class OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 2
- 238000004364 calculation method Methods 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 229910052839 forsterite Inorganic materials 0.000 description 2
- 238000009689 gas atomisation Methods 0.000 description 2
- 150000002431 hydrogen Chemical class 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- HCWCAKKEBCNQJP-UHFFFAOYSA-N magnesium orthosilicate Chemical compound [Mg+2].[Mg+2].[O-][Si]([O-])([O-])[O-] HCWCAKKEBCNQJP-UHFFFAOYSA-N 0.000 description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- 229910044991 metal oxide Inorganic materials 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000012299 nitrogen atmosphere Substances 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 229910052698 phosphorus Inorganic materials 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 229920002050 silicone resin Polymers 0.000 description 2
- 229910052717 sulfur Inorganic materials 0.000 description 2
- 239000000454 talc Substances 0.000 description 2
- 229910052623 talc Inorganic materials 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 238000004804 winding Methods 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- ILRRQNADMUWWFW-UHFFFAOYSA-K aluminium phosphate Chemical compound O1[Al]2OP1(=O)O2 ILRRQNADMUWWFW-UHFFFAOYSA-K 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 239000004327 boric acid Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 1
- 239000008116 calcium stearate Substances 0.000 description 1
- 235000013539 calcium stearate Nutrition 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 239000008119 colloidal silica Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 238000010790 dilution Methods 0.000 description 1
- 239000012895 dilution Substances 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 210000003746 feather Anatomy 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 238000003384 imaging method Methods 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
- HGPXWXLYXNVULB-UHFFFAOYSA-M lithium stearate Chemical compound [Li+].CCCCCCCCCCCCCCCCCC([O-])=O HGPXWXLYXNVULB-UHFFFAOYSA-M 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- GVALZJMUIHGIMD-UHFFFAOYSA-H magnesium phosphate Chemical compound [Mg+2].[Mg+2].[Mg+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O GVALZJMUIHGIMD-UHFFFAOYSA-H 0.000 description 1
- 239000004137 magnesium phosphate Substances 0.000 description 1
- 229910000157 magnesium phosphate Inorganic materials 0.000 description 1
- 229960002261 magnesium phosphate Drugs 0.000 description 1
- 235000010994 magnesium phosphates Nutrition 0.000 description 1
- 239000000696 magnetic material Substances 0.000 description 1
- 230000005415 magnetization Effects 0.000 description 1
- 239000011572 manganese Substances 0.000 description 1
- 238000000691 measurement method Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229910001463 metal phosphate Inorganic materials 0.000 description 1
- 238000000386 microscopy Methods 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
- 150000002910 rare earth metals Chemical class 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 238000012552 review Methods 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000010998 test method 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
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 1
Classifications
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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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/05—Metallic powder characterised by the size or surface area of the particles
-
- 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
- B22F1/05—Metallic powder characterised by the size or surface area of the particles
- B22F1/052—Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
-
- 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
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/102—Metallic powder coated with organic material
-
- 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
- C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
- C22C33/0264—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements the maximum content of each alloying element not exceeding 5%
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/001—Ferrous alloys, e.g. steel alloys containing N
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/004—Very low carbon steels, i.e. having a carbon content of less than 0,01%
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
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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
- H01F1/12—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 soft-magnetic materials
- H01F1/14—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 soft-magnetic materials metals or alloys
- H01F1/147—Alloys characterised by their composition
- H01F1/14766—Fe-Si based alloys
- H01F1/14791—Fe-Si-Al based alloys, e.g. Sendust
-
- 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
- H01F1/12—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 soft-magnetic materials
- H01F1/14—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 soft-magnetic materials metals or alloys
- H01F1/20—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 soft-magnetic materials metals or alloys in the form of particles, e.g. powder
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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
- H01F1/12—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 soft-magnetic materials
- H01F1/14—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 soft-magnetic materials metals or alloys
- H01F1/20—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 soft-magnetic materials metals or alloys in the form of particles, e.g. powder
- H01F1/22—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 soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
- H01F1/24—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 soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
- H01F1/26—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 soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated by macromolecular organic substances
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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
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/02—Details of the magnetic circuit characterised by the magnetic material
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Power Engineering (AREA)
- Dispersion Chemistry (AREA)
- Physics & Mathematics (AREA)
- Manufacturing & Machinery (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Electromagnetism (AREA)
- Soft Magnetic Materials (AREA)
- Powder Metallurgy (AREA)
Description
(1)成形圧:0.98GN/m2で成形した圧粉体の断面で、電子線後方散乱回折(EBSD)を用いて結晶方位を測定し、前記結晶方位の測定結果からEBSD解析ソフトを用いて算出したKAM(Kernel Average Misorientation)の平均値が3.00°以下となる圧粉磁芯用鉄粉。
(2)(1)において、粒径:45μm以下の粒子を10質量%以下有し、
平均硬さがビッカース硬さで80HV0.025以下であり、
単位面積当たりの介在物個数(個/m2)と介在物のメジアン径D50(m)との積が10000(個/m)以下であり、
見掛け密度:4.0Mg/m3以上である圧粉磁芯用鉄粉。
(3)(1)または(2)において、質量%で、Al:0.01%以下、Si:0.01%以下、Mn:0.1%以下、Cr:0.05%以下、含有し、残部Feおよび不可避的不純物からなる圧粉磁芯用鉄粉。
(4)(1)ないし(3)のいずれかにおいて、表面に絶縁被覆層を有する圧粉磁芯用鉄粉。
(5)(4)において、前記絶縁被覆層が、シリコーン被覆層である圧粉磁芯用鉄粉。
(6)(5)において、前記シリコーン被覆層が、圧粉磁芯用鉄粉100質量部に対して0.1質量部以上である圧粉磁芯用鉄粉。
(7)鉄を主成分とする組成の溶湯を、アトマイズ粉末とするアトマイズ工程と、該アトマイズ粉末に脱炭・還元焼鈍処理を施す脱炭・還元焼鈍処理工程と、脱炭・還元焼鈍処理済みの前記アトマイズ粉末に解砕処理を施す解砕処理工程と、該解砕処理を施された前記アトマイズ粉末の歪取りを行う歪取熱処理工程と、を施して、鉄を主成分とする粉末とする圧粉磁芯用鉄粉の製造方法であって、前記解砕処理を、回転体による解砕装置を用い、該回転体の周速と処理時間との積算値(周速(m/s)×処理時間(s))が1000m以上22000m以下である処理とする圧粉磁芯用鉄粉の製造方法。
(8)(7)において、質量%で、Al:0.01%以下、Si:0.01%以下、Mn:0.1%以下、Cr:0.05%以下に調整され、残部Feおよび不可避的不純物からなる溶湯である圧粉磁芯用鉄粉の製造方法。
(9)(7)または(8)において、得られた前記鉄を主成分とする粉末の表面に、絶縁被覆層を形成する絶縁被覆処理を施すことを特徴とする圧粉磁芯用鉄粉の製造方法。
(10)(9)において、前記絶縁被覆層が、シリコーン樹脂被覆層である圧粉磁芯用鉄粉の製造方法。
(11)(10)において、前記シリコーン樹脂被覆層が、前記鉄を主成分とする粉末100質量部に対し0.1質量部以上である圧粉磁芯用鉄粉の製造方法。
(12)対象とする鉄粉を成形して圧粉体とし、該圧粉体の断面について、電子線後方散乱回折(EBSD)を用いて結晶方位を測定し、前記結晶方位の測定結果からEBSD解析ソフトを用いて算出したKAM(Kernel Average Misorientation)により、低鉄損圧粉磁芯を製造できる鉄粉を評価する圧粉磁芯用鉄粉の選別方法。
(13)対象とする鉄粉を、成形圧:0.98GN/m2で成形して圧粉体とし、該圧粉体の断面について、電子線後方散乱回折(EBSD)を用いて結晶方位を測定し、前記結晶方位の測定結果からEBSD解析ソフトを用いて算出したKAM(Kernel Average Misorientation)の平均値が3.00°以下である場合を、低鉄損圧粉磁芯を製造できる鉄粉と評価する圧粉磁芯用鉄粉の選別方法。
また、成形圧を0.98GN/m2とすることで、成形圧を0.98GN/m2より低くする場合よりも、好適な鉄粉とそうでない鉄粉のKAMの差を大きくすることができ、鉄粉の良否判断を容易に行うことができる。
なお、実際に圧粉磁芯を成形する際は、この成形圧に限定されないことは言うまでもない。
水アトマイズ法にて、表1に示す成分を含有し、残部Feおよび不可避的不純物からなる組成の純鉄粉を作製した。
(1)見掛け密度
見掛け密度は、JIS Z 2504に準拠した方法で測定した。
(2)介在物測定
被測定物である鉄粉を、熱可塑性樹脂中に埋込み、鉄粉含有樹脂固形物とし、該鉄粉含有樹脂固形物の断面を研磨し腐蝕し、走査型電子顕微鏡(倍率:1000〜5000倍)を用いて鉄粉粒子の断面組織を反射電子像で観察し、少なくとも5視野以上の複数視野で撮像した。得られた各視野での写真を、画像処理して、介在物の単位面積当たりの個数(個/m2)を求めた。また、介在物の粒径分布を求め、その前後で粒子個数が等しくなる粒径であるメジアン径D50(m)を求めた。各視野で得られた値を算術平均して、その平均値を当該鉄粉の値とした。なお、介在物の粒径は、各介在物の面積から求めた円相当直径を用いた。
(3)平均硬さ
被測定物である鉄粉を、熱可塑性樹脂中に埋込み、鉄粉含有樹脂固形物とし、該鉄粉含有樹脂固形物の断面を研磨し、硬さ測定用試片とした。得られた硬さ測定用試片について、JIS Z 2244の規定に準拠して、ビッカース硬さ計(荷重:25gf(0.245N))を用いてビッカース硬さHV0.025を測定した。硬さ測定は、各粒子につき1点とし、少なくとも10個の粉末粒子の硬さを測定し、その平均値を、当該鉄粉の硬さとした。
(実施例2)
実施例1で使用した鉄粉No.1(表2参照)を原料粉末として用い、原料粉末にシリコーンによる絶縁被覆処理を施した。シリコーンを、トルエンに溶解させて、樹脂分が1.0質量%となるような樹脂希釈溶液を作製し、ついで、鉄粉100質量部に対し樹脂分が0.10〜0.25質量部となるように、鉄粉と樹脂希釈溶液とを混合し、大気中で乾燥させた。さらに大気中で、200℃×120minの樹脂焼付け処理を行い、鉄粉の粒子表面にシリコーンによる絶縁被覆層を形成した絶縁被覆鉄粉とした。
Claims (7)
- 質量%で、Al:0.01%以下、Si:0.01%以下、Mn:0.1%以下、Cr:0.05%以下、含有し、残部Feおよび不可避的不純物からなり、
成形圧:0.98GN/m2で成形した圧粉体の断面で、電子線後方散乱回折(EBSD)を用いて結晶方位を測定し、前記結晶方位の測定結果からEBSD解析ソフトを用いて算出したKAM(Kernel Average Misorientation)の平均値が3.00°以下となる圧粉磁芯用鉄粉。 - 粒径:45μm以下の粒子を10質量%以下有し、
平均硬さがビッカース硬さで80HV0.025以下であり、
単位面積当たりの介在物個数(個/m2)と介在物のメジアン径D50(m)との積が10000(個/m)以下であり、
見掛け密度:4.0Mg/m3以上である請求項1に記載の圧粉磁芯用鉄粉。 - 表面に絶縁被覆層を有する請求項1または2に記載の圧粉磁芯用鉄粉。
- 前記絶縁被覆層が、シリコーン被覆層である請求項3に記載の圧粉磁芯用鉄粉。
- 前記シリコーン被覆層が、圧粉磁芯用鉄粉100質量部に対して0.1質量部以上である請求項4に記載の圧粉磁芯用鉄粉。
- 質量%で、Al:0.01%以下、Si:0.01%以下、Mn:0.1%以下、Cr:0.05%以下、含有し、残部Feおよび不可避的不純物からなる組成を有する対象とする鉄粉を成形して圧粉体とし、該圧粉体の断面について、電子線後方散乱回折(EBSD)を用いて結晶方位を測定し、前記結晶方位の測定結果からEBSD解析ソフトを用いて算出したKAM(Kernel Average Misorientation)により、低鉄損圧粉磁芯を製造できる鉄粉を評価する圧粉磁芯用鉄粉の選別方法。
- 質量%で、Al:0.01%以下、Si:0.01%以下、Mn:0.1%以下、Cr:0.05%以下、含有し、残部Feおよび不可避的不純物からなる組成を有する対象とする鉄粉を、成形圧:0.98GN/m2で成形して圧粉体とし、該圧粉体の断面について、電子線後方散乱回折(EBSD)を用いて結晶方位を測定し、前記結晶方位の測定結果からEBSD解析ソフトを用いて算出したKAM(Kernel Average Misorientation)の平均値が3.00°以下である場合を、低鉄損圧粉磁芯を製造できる鉄粉と評価する圧粉磁芯用鉄粉の選別方法。
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