JP6310639B2 - Manufacturing method of magnetic parts - Google Patents

Description

    The present invention relates to a magnetic component with improved wear resistance, corrosion resistance, and magnetic properties, an electronic component using the magnetic component, and a method for manufacturing the magnetic component.

  Magnetic parts used for electronic parts such as electromagnetic relays (hereinafter also referred to as relays) are plated with Ni for the purpose of imparting corrosion resistance. FIG. 30 is a perspective view of a conventional relay 200. The relay 200 includes a yoke 201, an iron piece 202, and an iron core 203 as magnetic parts to which Ni plating is applied. Ni plating covers the surface of the component, and in order to improve corrosion resistance, it is necessary to increase the thickness of the Ni plating. However, an increase in Ni plating film thickness can affect the fitting of components.

  A problem also arises when the Ni plating film is thin. For example, in a relay with a seal structure, nitric acid is generated by arc heat when an electrical contact is opened and closed in a state where a high voltage / high current load is applied. The plating is eroded by nitric acid, and patina is generated on the surface of the magnetic component. When the reaction proceeds, the relay becomes inoperable.

  Further, for example, in a relay having a sliding portion (hinge), there is a problem that the operating characteristics greatly vary because the hinge portion is mechanically consumed by sliding. In order to solve the problem, the relay is assembled by applying lubricating oil to the hinge portion. However, since the lubricating oil is usually not reapplied until the relay reaches the end of its life, it is inevitable that the wear progresses over time.

  Therefore, a technique using chromium has been proposed as a technique for solving the problem of film thickness and corrosion resistance of Ni plating. Patent Document 1 describes a soft magnetic stainless steel for a relay iron core containing chromium. Patent Document 2 describes a relay electromagnetic material containing chromium. Since the stainless steel described in Patent Document 1 and the electromagnetic material described in Patent Document 2 are configured as materials containing chromium, the problem of film thickness does not occur.

  Further, as a technique for solving the problem of wear resistance, a technique using chromium has been proposed. Patent Documents 3 to 5 describe chains and chain pins that have been subjected to chromizing treatment. In the techniques described in Patent Documents 3 to 5, wear resistance is improved by diffusing and infiltrating chromium into the surface of the chain or the chain pin. In addition, when chromizing treatment is performed, chromium diffuses and penetrates into the base material, so that an increase in film thickness can be suppressed.

  As a method of the above chromizing treatment, for example, there is a technique described in Patent Document 6. Patent Document 6 describes a technique for forming a chromium diffusion layer using a mixture of metallic Cr powder and metallic powder composed of one or more of Zn, W, Ti, and Mo. In the technique described in Patent Document 6, the chromium diffusion layer can be remarkably increased, and as a result, the corrosion resistance is improved.

JP-A-8-269640 (released on October 15, 1996) JP 2003-27190 A (published January 29, 2003) JP 10-311381 A (published on November 24, 1998) Japanese Patent Laying-Open No. 2006-132737 (published May 25, 2006) JP 2008-281027 A (released on November 20, 2008) Japanese Patent Laid-Open No. 5-5173 (published January 14, 1993)

  However, the conventional technology as described above has a problem in that it cannot provide a method for manufacturing a magnetic component having excellent wear resistance, corrosion resistance, and magnetic properties.

  For example, the techniques described in Patent Documents 1 and 2 are alloys containing chromium. Since chromium is uniformly present in the alloy, the metal structure of the base material is not sufficiently grown. Therefore, although the said alloy is described in patent documents 1 and 2 as a component for relays, the said component does not have sufficient magnetism. In other words, it is still not enough as a relay component.

  In addition, for example, the chains and chain pins described in Patent Documents 3 to 5 are required to contain a large amount of carbon in the material in order to increase the hardness. Even in such a case, the metal structure cannot be sufficiently grown, and sufficient magnetism cannot be imparted to the material.

  Moreover, in the technique described in Patent Document 6, the chromium diffusion layer is extremely thick, so that the magnetic resistance is increased. Therefore, it is difficult to apply the technique described in Patent Document 6 to magnetic parts.

  The present invention has been made in view of the above-described conventional problems, and an object of the present invention is to provide a method of manufacturing a magnetic component having excellent wear resistance, corrosion resistance, and magnetic characteristics.

  In order to solve the above problems, a magnetic component according to the present invention is a magnetic component including an iron-based component obtained by processing an iron-based material, and the iron-based component includes Cr, V, Ti, Al, and Provided with an alloy layer formed by performing diffusion treatment of one or more elements selected from the group consisting of Si at a treatment time of 5 hours to 15 hours and a treatment temperature of 750 ° C. to 950 ° C. It is characterized by that.

  According to the above configuration, the alloy layer in which one or more elements selected from the group consisting of Cr, V, Ti, Al, and Si are diffused and permeated on the surface of the iron-based component formed by processing the iron-based material. By forming, sufficient hardness can be imparted to the magnetic component. As a result, a magnetic component exhibiting excellent wear resistance can be provided.

  In addition, by forming the alloy layer on the surface of the iron-based component, excellent corrosion resistance against nitric acid or the like can be imparted to the magnetic component.

  Furthermore, by performing the diffusion and permeation treatment under conditions of a specific time and a specific temperature, the thickness of the alloy layer can be controlled and the metal structure of the iron-based component can be grown. As a result, the magnetic component exhibits excellent magnetic properties even though the alloy layer is formed using a non-magnetic element such as Cr, V, Ti, Al, and Si.

  Further, since the alloy layer is formed by diffusion penetration, the thickness of the component itself does not increase significantly. Therefore, the alloy layer does not affect the fitting of components.

  That is, according to the said structure, the magnetic component which has the outstanding abrasion resistance, corrosion resistance, and a magnetic characteristic can be provided.

  In the magnetic component according to the present invention, the treatment time is preferably 8 hours or more and 10 hours or less.

  According to the above configuration, the thickness of the alloy layer can be sufficient to provide wear resistance and corrosion resistance, and the metal structure can be sufficiently grown. A magnetic component having corrosion resistance and magnetic properties can be provided.

  In the magnetic component according to the present invention, the carbon content of the iron-based material is preferably 0% by weight or more and 0.15% by weight or less.

  According to the said structure, since the carbon content of an iron-type material is small, the metal structure of the iron-type components formed by processing an iron-type material can fully be grown. That is, it is possible to provide a magnetic component having more excellent magnetic characteristics.

  In the magnetic component according to the present invention, the carbon content of the iron-based material is preferably 0% by weight or more and less than 0.05% by weight.

  According to the said structure, since the carbon content of an iron-type material is small, the metal structure of the iron-type components formed by processing an iron-type material can fully be grown. That is, it is possible to provide a magnetic component having more excellent magnetic characteristics.

  In the magnetic component according to the present invention, the crystal grain of the iron-based component is preferably grown to a ferrite grain size number 1 or less as defined in JIS G0551 (2005).

  According to the said structure, since the metal structure of the iron-type component formed by processing the said iron-type material can fully be grown, the magnetic component which has the outstanding magnetic characteristic can be provided.

  In order to solve the above problems, the electronic component according to the present invention preferably includes the magnetic component according to the present invention.

  According to the above configuration, since the magnetic component has excellent wear resistance, it is possible to provide an electronic component having a long life with little wear due to mechanical sliding.

  In addition, since the magnetic component has excellent corrosion resistance, even when nitric acid is generated in the electronic component due to arc heat, an electronic component exhibiting excellent corrosion resistance against the nitric acid can be provided.

  Furthermore, since a magnetic component having excellent magnetic properties can be used as an electromagnet or the like, an electronic component having excellent magnetic properties can be provided.

  In order to solve the above-described problems, a method for manufacturing a magnetic component according to the present invention is a method for manufacturing a magnetic component including an iron-based component obtained by processing an iron-based material. Including an alloy layer forming step of diffusing and penetrating one or more elements selected from the group consisting of Ti, Al, and Si and forming an alloy layer. It is characterized by being carried out at a treatment time of not less than 15 hours and not more than 15 hours and a treatment temperature of not less than 750 ° C. and not more than 950 ° C.

  According to the above configuration, the alloy layer in which one or more elements selected from the group consisting of Cr, V, Ti, Al, and Si are diffused and permeated on the surface of the iron-based component formed by processing the iron-based material. By forming, sufficient hardness can be imparted to the magnetic component. As a result, a magnetic component exhibiting excellent wear resistance can be manufactured.

  In addition, by forming the alloy layer on the surface of the iron-based component, excellent corrosion resistance against nitric acid or the like can be imparted to the magnetic component.

  Furthermore, by performing the diffusion and permeation treatment under conditions of a specific time and a specific temperature, the thickness of the alloy layer can be controlled and the metal structure of the iron-based component can be grown. As a result, the magnetic component exhibits excellent magnetic properties even though the alloy layer is formed using a non-magnetic element such as Cr, V, Ti, Al, and Si.

  Further, since the alloy layer is formed by diffusion penetration, the thickness of the component itself does not increase significantly. Therefore, the alloy layer does not affect the fitting of components.

  That is, according to the said structure, the magnetic component which has the outstanding abrasion resistance, corrosion resistance, and a magnetic characteristic can be manufactured.

  In addition, since the formation of the alloy layer and the growth of the metal structure can be performed in one step, the manufacturing process of the magnetic component can be simplified. As a result, the cost for manufacturing the magnetic component can be reduced.

  In the method for manufacturing a magnetic component according to the present invention, the treatment time is preferably 8 hours or more and 10 hours or less.

  According to the above configuration, the thickness of the alloy layer can be sufficient to provide wear resistance and corrosion resistance, and the metal structure can be sufficiently grown. Magnetic parts having corrosion resistance and magnetic properties can be manufactured.

  In the method for manufacturing a magnetic component according to the present invention, the carbon content of the iron-based material is preferably 0% by weight or more and 0.15% by weight or less.

  According to the said structure, since the carbon content of an iron-type material is small, the metal structure of the iron-type components formed by processing an iron-type material can fully be grown. That is, a magnetic component having more excellent magnetic characteristics can be manufactured.

  In the method for manufacturing a magnetic component according to the present invention, the carbon content of the iron-based material is preferably 0% by weight or more and less than 0.05% by weight.

  According to the said structure, since the carbon content of an iron-type material is small, the metal structure of the iron-type components formed by processing an iron-type material can fully be grown. That is, a magnetic component having more excellent magnetic characteristics can be manufactured.

  In the alloy layer forming step, it is preferable to grow the crystal grains of the iron-based component until the ferrite crystal grain size number 1 or less as defined in JIS G0551 (2005).

  According to the above configuration, since the metal structure of the iron-based component formed by processing the iron-based material can be sufficiently grown, a magnetic component having excellent magnetic properties can be manufactured.

  The magnetic component according to the present invention is a magnetic component including an iron-based component obtained by processing an iron-based material, and the iron-based component is one selected from the group consisting of Cr, V, Ti, Al, and Si. It is a structure provided with the alloy layer formed by performing the process which carries out the diffusion penetration | infiltration of the above element at the processing time of 5 hours or more and 15 hours or less and the processing temperature of 750 degreeC or more and 950 degrees C or less.

  Therefore, a magnetic component having excellent wear resistance, corrosion resistance, and magnetic properties can be provided.

It is the schematic which shows the manufacturing method of the magnetic component which concerns on one Embodiment of this invention. It is the schematic which compared the manufacturing method (a) of the conventional type magnetic component, and the manufacturing method (b) of the magnetic component which concerns on this invention. It is a figure which shows the external appearance of the magnetic component which concerns on one Embodiment of this invention. It is sectional drawing of the electromagnet apparatus provided with the magnetic component which concerns on one Embodiment of this invention. It is a disassembled perspective view of the electronic component which concerns on one Embodiment of this invention. It is a perspective view of the electromagnet apparatus with which the electronic component which concerns on one Embodiment of this invention was equipped. It is a perspective view of the iron piece with which the electronic component which concerns on one Embodiment of this invention was equipped. It is the schematic which shows the external appearance of the test piece used for the measurement of the coercive force in the Example of this invention. It is the schematic which shows the measuring method of the attraction | suction force in the Example of this invention. (A)-(e) is the schematic of the method of winding a coil around the test piece used for the measurement of the coercive force in the Example of this invention, (f) is the schematic which shows the external appearance of the test piece which wound the coil (G) shows a cross-sectional view taken along line AA ′ of (f). It is a figure which shows the example of the BH curve used for the measurement of a coercive force. It is a figure which shows the relationship between the stroke ST and the attraction | suction force F in the Example of this invention. It is a figure which shows the metal structure obtained in the Example of this invention. (A) is a figure which shows the chromium concentration analysis value of the alloy layer cross section in Example 6 of this invention, (b) is a figure which shows the vanadium concentration analysis value of the alloy layer cross section in Example 7 of this invention, (C) is a figure which shows the aluminum concentration analysis value of the alloy layer cross section in Example 8 of this invention. (A)-(c) is a figure which shows the chromium concentration analysis value of the alloy layer cross section in Examples 9-11 of this invention, respectively, (d) is the vanadium density | concentration of the alloy layer cross section in Example 12 of this invention. It is a figure which shows an analysis value, (e) is a figure which shows the aluminum concentration analysis value of the alloy layer cross section in Example 13 of this invention. It is a figure which shows the test result of Example 14 and Comparative Examples 7-8 of this invention. It is a figure which shows the test result of the comparative example 7 of this invention. It is a figure which shows the test result of the comparative example 8 of this invention. It is a figure which shows the test result of Example 14 of this invention. It is a figure which shows the test result of Example 15 and Comparative Examples 9-10 of this invention. It is a figure which shows the test result of the comparative example 9 of this invention. It is a figure which shows the test result of the comparative example 10 of this invention. It is a figure which shows the test result of Example 15 of this invention. It is a figure which shows the test result of the comparative example 11 of this invention. It is a figure which shows the test result of Example 16 of this invention. It is a figure which shows the test result of Example 17 of this invention. It is a figure which shows the test result of Example 18 of this invention. It is a figure which shows the test result of Example 19 of this invention. It is a figure which shows the test result of Example 20 and Comparative Example 12 of this invention. It is a perspective view which shows the conventional relay.

  Hereinafter, although an example of an embodiment of the invention is explained in detail, the present invention is not limited to these. For convenience of explanation, members having the same function are denoted by the same reference numerals and description thereof is omitted. In addition, the x-axis, y-axis, and z-axis in the drawings define the direction in the three-dimensional space in each drawing.

[Method of manufacturing magnetic parts]
A method of manufacturing a magnetic component according to the present invention is a method of manufacturing a magnetic component including an iron-based component obtained by processing an iron-based material, and the iron-based component is made of Cr, V, Ti, Al, and Si. A process of diffusing and penetrating one or more elements selected from the group, and including an alloy layer forming step of forming an alloy layer, wherein the process of diffusing and penetrating the elements includes a treatment time of 5 hours to 15 hours, And it is a manufacturing method of the magnetic component characterized by performing at the process temperature of 750 degreeC or more and 950 degrees C or less.

  According to the above configuration, the alloy layer in which one or more elements selected from the group consisting of Cr, V, Ti, Al, and Si are diffused and permeated on the surface of the iron-based component formed by processing the iron-based material. By forming, sufficient hardness can be imparted to the magnetic component. As a result, a magnetic component exhibiting excellent wear resistance can be manufactured.

  Moreover, according to the said structure, the corrosion resistance with respect to nitric acid etc. can be provided to a magnetic component by forming the said alloy layer in the surface of an iron-type component.

  Furthermore, by performing the diffusion and permeation treatment under conditions of a specific time and a specific temperature, the thickness of the alloy layer can be controlled and a metal structure can be grown. As a result, an increase in magnetic resistance due to the alloy layer can be suppressed, and excellent magnetic properties can be imparted to the magnetic component.

  That is, according to the said structure, the magnetic component which has the outstanding abrasion resistance, corrosion resistance, and a magnetic characteristic can be manufactured. Below, the manufacturing method of the magnetic component which concerns on this invention is demonstrated in detail.

<Iron parts>
In the method for manufacturing a magnetic component according to the present invention, an iron-based component obtained by processing an iron-based material is used. In this specification, “iron-based material” means all iron alloys mainly composed of iron. Examples of the iron-based material include pure iron and steel. Examples of the steel include cold rolled steel, hot rolled steel, and electromagnetic steel. The iron-based material may contain silicon, for example, a silicon steel plate. The shape of the iron-based material is not particularly limited, and examples thereof include a band shape and a rod shape.

  In the present specification, the “iron-based component” means a component obtained by processing an iron-based material into a desired shape. Although the method of processing an iron-type component from an iron-type material is not specifically limited, For example, press work etc. are mentioned. Further, the shape and size of the iron-based component can be appropriately determined according to the purpose of use.

  The carbon content of the iron-based material is preferably 0% by weight or more and 0.15% by weight or less, more preferably 0% by weight or more and less than 0.05% by weight, and 0% by weight or more and 0.01% by weight or less. Particularly preferred is less than% by weight. According to the above configuration, since the carbon content of the iron-based material is small, the metal structure of the iron-based component formed by processing the iron-based material is sufficiently grown by performing the heat treatment in the alloy layer forming process described later. Can be made. Therefore, a magnetic component having excellent magnetic properties can be provided.

  Unless otherwise specified, in this specification, the “surface of the iron-based component” means at least a part of all surfaces of the iron-based component. Preferably, the alloy layer is formed on all surfaces of the iron-based component. Further, the surface may be one in which the element diffuses and penetrates a part of the surface, but it is preferable that the element diffuses and penetrates as much as possible in the surface, and the element diffuses and penetrates the entire surface. More preferably. According to the said structure, the magnetic component which shows the outstanding abrasion resistance and corrosion resistance in all the surfaces of an iron-type component, and also has the outstanding magnetic characteristic can be provided.

<Elements that diffuse and penetrate into iron parts>
The method of manufacturing a magnetic component according to the present invention diffuses and penetrates one or more elements selected from the group consisting of Cr, V, Ti, Al, and Si into the iron-based component. By diffusing and penetrating the element into the iron-based component, an alloy layer can be formed on the surface of the iron-based component.

  One or more elements selected from the group consisting of Cr, V, Ti, Al, and Si may be used, for example, in the form of a powder. As the powder, a powder of one element selected from the group consisting of Cr, V, Ti, Al, and Si may be used, and a powder containing two or more of the above elements is used. Also good. When the powder containing two or more elements is used, the mixing ratio of the two or more elements is arbitrary as long as excellent wear resistance, corrosion resistance, and magnetic properties can be realized. The powder 2 may be a single powder of one or more elements selected from the group consisting of Cr, V, Ti, Al, and Si, or may be a powder of a compound or alloy containing the above elements. Good. As an alloy containing the said element, the alloy of the said element and iron is mentioned, for example.

  Further, the powder containing one or more elements selected from the group consisting of Cr, V, Ti, Al, and Si may be introduced as a penetrant mixed with other materials. For example, a powder containing the above element, alumina powder, and ammonium chloride powder may be mixed at an arbitrary ratio to form a penetrant. According to the said structure, a diffusion penetration process can be performed more efficiently.

<Alloy layer formation process>
The alloy layer forming step will be described in detail below.

  FIG. 1 is a schematic view showing a method of manufacturing a magnetic component according to the present invention. First, an iron-based component 1 formed by processing an iron-based material is introduced into the box 6. Here, the iron-based components 1 introduced into the box are preferably arranged so as not to contact each other. According to the said structure, the thickness of the alloy layer formed becomes substantially uniform in the whole surface of the iron-type components 1, and it is not necessary to worry about the dispersion | variation in the film thickness by the site | part which generate | occur | produces in Ni plating goods.

  Thereafter, the powder 2 containing one or more elements selected from the group consisting of Cr, V, Ti, Al, and Si is introduced into the box 6. Here, the iron-based component 1 is embedded in the powder 2.

  Next, the box 6 is placed in the furnace 7, and the powder 2 is diffused and penetrated into the iron-based component 1 at a processing time and a processing temperature described later. According to the combination of the treatment time and the treatment temperature, one or more elements selected from the group consisting of Cr, V, Ti, Al, and Si are diffused and penetrated into the iron-based component to form an alloy layer. The metal structure of the iron-based component can be grown. In the present specification, the process of diffusing and penetrating one or more elements selected from the group consisting of Cr, V, Ti, Al, and Si into the iron-based component is also simply referred to as “diffusion penetrating process”. Further, in the present specification, a process for diffusing and penetrating Cr in particular is referred to as “chromizing”.

  After the diffusion and permeation treatment, the box 6 is taken out from the furnace 7 and the iron-based component 1 is taken out from the box 6. Thereafter, the iron-based component 1 may be appropriately washed and dried.

<Processing time and processing temperature>
In the diffusion permeation treatment, the treatment time is 5 hours or more and 15 hours or less, preferably 8 hours or more and 10 hours or less. In the diffusion permeation treatment, the treatment temperature is 750 ° C. or more and 950 ° C. or less, preferably 750 ° C. or more and 900 ° C. or less, more preferably 750 ° C. or more and less than 900 ° C., and 750 ° C. or more and 850 ° C. It is particularly preferred that

  If the treatment time is 5 hours or more and the treatment temperature is 750 ° C. or more, the thickness of the alloy layer can be made sufficient to provide wear resistance and corrosion resistance, It can be grown sufficiently. Further, if the treatment time is 15 hours or less and the treatment temperature is 950 ° C. or less, the thickness of the alloy layer is set to a thickness that does not increase the magnetic resistance and does not hinder the growth of the metal structure. Can be controlled.

  What is the thickness of the alloy layer that is “thickness sufficient to provide wear resistance and corrosion resistance” and “thickness that does not increase the magnetic resistance and does not hinder the growth of the metal structure”? For example, they are 5 micrometers or more and 60 micrometers or less, More preferably, they are 5 micrometers or more and 35 micrometers or less.

  Further, in the alloy layer forming step, by setting the processing time and the processing temperature as described above, the crystal grains of the iron-based component are grown until the ferrite crystal grain size number 1 or less defined in JIS G0551 (2005) is reached. It is preferable. In the present specification, the particle number of 1 or less means that the particle number is 1, 0, -1, -2,. According to the said structure, since the size of the crystal grain of an iron-type component is large and the metal structure has fully grown, the magnetic component which has the outstanding magnetic characteristic can be provided. Further, in the present specification, the “crystal grain size of the iron-based part” means the crystal grain size of the region inside the alloy layer as viewed from the surface of the iron-based part.

  In this specification, “inside” or “lower layer” from the alloy layer when viewed from the surface of the iron-based component, in other words, from the group consisting of Cr, V, Ti, Al, and Si in the iron-based component. It is a region where one or more selected elements are not diffused and permeated. For example, when the alloy layer is formed on all surfaces of the iron-based component, the region existing “inside” or “lower layer” from the alloy layer as viewed from the surface of the iron-based component is surrounded by the alloy layer. It is an area.

<Comparison with Ni plating product manufacturing method>
According to the method for manufacturing a magnetic component according to the present invention, the manufacturing process of the magnetic component can be simplified. As a result, the cost for manufacturing the magnetic component can be reduced. FIG. 2 is a schematic diagram comparing a conventional Ni-plated product manufacturing method (FIG. 2A) and a magnetic component manufacturing method according to the present invention (FIG. 2B). In the present specification, the conventional magnetic parts plated with Ni may be simply referred to as “Ni-plated product” or “current product”.

  In the conventional manufacturing method of Ni-plated products, first, a plate-shaped iron-based material is mainly pressed to create a predetermined shape product, and secondly, a non-oxidizing property is provided to provide necessary magnetic properties. Alternatively, heat treatment is performed by heating at 800 to 900 ° C. for 15 to 30 minutes in a reducing atmosphere. In order to improve the magnetic properties, it is desirable that the metal crystal grains are large, and for that purpose, it is desirable to heat for a longer time, but in general, the minimum is about 15 minutes from the viewpoint of cost performance. Third, Ni plating is performed for the purpose of improving the corrosion resistance of the parts. Since the above three steps have different purposes and methods, none of them can be omitted and are essential steps for manufacturing a magnetic component.

  On the other hand, in the method for manufacturing a magnetic component according to the present invention, since the growth of the metal structure and the formation of the alloy layer can be performed at the same time by performing the diffusion permeation treatment with heat treatment, the press and diffusion permeation treatment are performed in two steps. It will be over. Therefore, it is possible not only to obtain a magnetic component having both wear resistance and corrosion resistance superior to those of conventional Ni-plated products while obtaining desired magnetic characteristics, but also to simplify the process.

  In addition, Ni plating is performed by electroplating, but instead of plating parts one by one, in order to minimize costs, a certain number of them are put together in a basket and rotated to make a plurality of parts. At the same time, plating is performed. However, in the above method, the component is easily deformed due to the weight of the component and the displacement at the time of rotation, which causes a defective product. In addition, plating is performed on the entire surface of the component. However, since the plating proceeds while the surfaces of the components are rubbed together, there is a large variation in the plating film thickness for each component depending on the shape of the component. In particular, the film thickness tends to vary. Therefore, in order to ensure corrosion resistance on the entire surface of the component, the actual situation is that the average plating film thickness of the entire component must be increased more than necessary. Although the above plating method can perform a large amount of batch processing, the plating film thickness that can be formed is relatively thin, and in consideration of the variation in film thickness, the plating is repeated twice to obtain an average film thickness of about 5 to 10 μm. It is common. In this case, substantially four steps are required to manufacture a product from the material.

  On the other hand, in the method of manufacturing a magnetic component according to the present invention, since the processing is not performed while rotating in a basket as in the case of performing Ni plating, the deformation of the component does not occur. Furthermore, since the thickness of the alloy layer generated by the diffusion permeation treatment is stable on the entire surface of the component, the amount of dimensional change is stable, and the fitting of each component is not adversely affected. Therefore, it is possible to prevent an assembly failure due to the thickness variation seen in the conventional Ni plating.

[Magnetic parts]
The magnetic component according to the present invention can be manufactured by the method for manufacturing a magnetic component according to the present invention. Moreover, the magnetic component according to the present invention is a magnetic component including an iron-based component formed by processing an iron-based material, for example, and the iron-based component is formed on the surface of the iron-based component with Cr, V, Ti. And an alloy layer in which one or more elements selected from the group consisting of Al, and Si are diffused and permeated, and the thickness of the alloy layer may be not less than 5 μm and not more than 60 μm.

  The magnetic parts are used for electronic parts such as relays and switches, for example. Examples of the magnetic component include a yoke 3 (FIG. 3A), an iron piece 4 (FIG. 3B), and an iron core 5 (FIG. 3C) used for a relay. The magnetic component may be an iron-based component itself in which an alloy layer described later is formed, or may be a combination of another component with the iron-based component. FIG. 4 is a cross-sectional view of the electromagnet device 10 described later, and shows the positional relationship between the yoke 3, the iron piece 4, and the iron core 5 in the electromagnet device 10.

  In the present specification, “magnetic” or “magnetic property” means a property having an attractive force and a coercive force, which will be described later. In addition, excellent magnetic or magnetic properties mean that it has at least the same attractive force and coercive force as those of conventional magnetic parts plated with Ni.

<Alloy layer>
In the magnetic component according to the present invention, the iron-based component is an alloy in which one or more elements selected from the group consisting of Cr, V, Ti, Al, and Si are diffused and penetrated on the surface of the iron-based component. For example, the alloy layer has a thickness of 5 μm or more and 60 μm or less.

  According to the said structure, sufficient hardness can be provided to the iron-type components formed by processing an iron-type material. As a result, a magnetic component having excellent wear resistance can be provided.

  Further, for example, in a relay having a seal structure, nitric acid is generated by arc heat when an electrical contact is opened and closed in a state where a high voltage and high current load is applied. As a result, in a conventional magnetic part subjected to Ni plating, the plating is eroded by nitric acid, and patina is generated on the surface of the magnetic part. On the other hand, since the magnetic component according to the present invention has the alloy layer, generation of patina can be suppressed. As a result, a magnetic component having excellent corrosion resistance can be provided.

  In this specification, the “alloy layer” is formed by diffusing and penetrating one or more elements selected from the group consisting of Cr, V, Ti, Al, and Si from the surface to the inside of the iron-based component. Means layer. The alloy layer may contain a compound such as carbon derived from the element and an iron-based material.

  Since the alloy layer is formed by diffusion permeation, the thickness of the component itself does not increase significantly as in the case of using Ni plating. Therefore, the alloy layer does not affect the fitting of parts.

  The thickness of the alloy layer is preferably as thick as possible from the viewpoint of wear resistance and corrosion resistance. However, Cr, V, Ti, Al, and Si are non-magnetic materials, and when the alloy layer is thick, the magnetic resistance increases, which is not preferable for use as a magnetic component. Further, if the alloy layer is thick, the growth of the metal structure existing inside the alloy layer as viewed from the surface of the iron-based component is also prevented.

  The magnetic component according to the present invention has excellent wear resistance and corrosion resistance because, for example, the thickness of the alloy layer is 5 μm or more. Moreover, since the magnetic component has a thickness of the alloy layer of 60 μm or less, for example, an increase in magnetic resistance can be suppressed. Further, if the thickness of the alloy layer is 60 μm or less, the growth of the metal structure existing inside the alloy layer as viewed from the surface of the iron-based component is not hindered. Therefore, in the iron-based component, the metal structure is sufficiently grown. Therefore, according to the said structure, the magnetic component which has the outstanding abrasion resistance, corrosion resistance, and a magnetic characteristic can be provided.

  The thickness of the alloy layer is more preferably 5 μm or more and 35 μm or less. According to the above configuration, since the thickness of the alloy layer has less influence on the growth of the metal structure, it is possible to provide a magnetic component that has excellent wear resistance and corrosion resistance, and more excellent magnetic properties. .

  In addition, the thickness of an alloy layer can be measured from the cross section which cut | disconnected the arbitrary surfaces in which the alloy layer is formed in an iron-type component perpendicularly | vertically. For example, when the iron-based component is a rectangular parallelepiped, an arbitrary surface may be cut vertically and the thickness of the alloy layer may be measured in the formed rectangular cross section. For example, when the iron-based component is spherical, the cross section may be cut so as to include the center of the sphere, and the thickness of the alloy layer may be measured in the formed circular cross section.

  In the alloy layer, one element of Cr, V, Ti, Al, and / or Si may diffuse and penetrate, and two or more of the elements may diffuse and penetrate. When two or more elements are diffused and permeated into the alloy layer, the ratio of the two or more elements in the alloy layer is within a range where excellent wear resistance, corrosion resistance, and magnetic properties can be realized. Is optional.

  The total of the maximum contents of Cr, V, Ti, Al, and / or Si in the alloy layer is preferably 20% by weight to 65% by weight, and 20% by weight to 60% by weight. It is more preferable that According to the above configuration, since the content of the element in the alloy layer is an amount sufficient to provide wear resistance and corrosion resistance, and the amount that has less influence on magnetism, excellent wear resistance and It is possible to provide a magnetic component having corrosion resistance and more sufficient magnetism.

  The maximum value of the element content can be determined by element concentration analysis using, for example, an electron probe microanalyzer (EPMA). The “maximum value of element content” means the maximum value of the element content values measured by EPMA or the like at an arbitrary plurality of positions in the alloy layer. For example, in the alloy layer, the Cr content at an arbitrary position at a distance of 5 μm from the surface of the iron-based part is 50% by weight, and the Cr content at an arbitrary position at a distance of 10 μm from the surface of the iron-based part is When it is 10% by weight, the maximum value of the Cr content is 50% by weight.

  Furthermore, when two or more elements among the above elements are contained in the alloy layer, the maximum total content of each element is preferably 20 wt% to 65 wt%, and preferably 20 wt% to 60 wt%. More preferably, it is% by weight. For example, when Cr and V are diffused and permeated into the alloy layer, the sum of the maximum value of Cr content and the maximum value of V content is preferably in the above range.

[Electronic parts]
The magnetic component according to the present invention may be incorporated in an electronic component. According to the above configuration, since the magnetic component has excellent wear resistance, it is possible to provide an electronic component having a long lifetime with little wear due to mechanical sliding.

  In addition, according to the above configuration, since the magnetic component has excellent corrosion resistance, even when nitric acid is generated in the electronic component due to arc heat, an electronic component exhibiting excellent corrosion resistance against the nitric acid is provided. Can do.

  Furthermore, since a magnetic component having excellent magnetic properties can be used as an electromagnet or the like, an electronic component having excellent magnetic properties can be provided.

  Examples of the electronic component provided with the magnetic component according to the present invention include a relay and a switch. Examples of the relay include, but are not limited to, a seal-type relay and a relay provided with a hinge. The relay may include an electromagnet device having a magnetic component and a coil according to the present invention, and a contact that opens and closes in conjunction with excitation and demagnetization of the electromagnet device.

  According to the above configuration, since the magnetic component has excellent wear resistance, it is possible to provide a relay having a long life with little wear due to mechanical sliding. In addition, since the magnetic component has excellent corrosion resistance, even if nitric acid is generated in the relay due to arc heat accompanying opening and closing of the relay, a relay exhibiting excellent corrosion resistance against the nitric acid can be provided. Furthermore, since the magnetic component which shows the outstanding magnetic characteristic can be used as an electromagnet, the relay which has the outstanding relay characteristic can be provided.

  FIG. 5 is an exploded perspective view of the relay 100 according to the embodiment of the present invention. The relay 100 includes an electromagnet device 10 having a magnetic component and a coil 14, and a contact 9 that opens and closes in conjunction with excitation and demagnetization of the electromagnet device 10. The relay 100 may be composed of a base 21 and a case 22. The electromagnet device 10 and the contact 9 may be provided on the base 21. For example, the case 22 may be configured to fit to the outer edge of the base 21 and cover each component on the base 21.

  FIG. 6 is a perspective view of the electromagnet device 10. The electromagnet device 10 includes, for example, a yoke 3, an iron piece 4, and an iron core 5. However, the iron piece 4 is omitted in FIG. The electromagnet device 10 includes the magnetic component as at least one of the yoke 3, the iron piece 4, and the iron core 5. Preferably, the yoke 3, the iron piece 4, and the iron core 5 are all the magnetic parts. The coil 14 is wound around the iron core 5. In the present specification, a configuration including the iron core 5 and the coil 14 is also referred to as an electromagnet portion 10a.

  FIG. 7 is a perspective view of the iron piece 4. The iron piece 4 may include a hinge spring 24. The iron piece 4 may be assembled to the base 21 via the hinge spring 24.

  Although the structure of the said contact 9 is not specifically limited, For example, as FIG. 5 shows, it consists of the movable contact 9a with which the movable contact piece 8a was equipped, and the fixed contact 9b with which the fixed contact piece 8b was equipped. The movable contact piece 8 a and the fixed contact piece 8 b are assembled to the base 21. The movable contact piece 8a is connected to the iron piece 4 through, for example, an intermediate member (card 23). When a voltage is applied to the coil 14, the iron piece 4 is attracted to the iron core 5 with the excitation of the electromagnet portion 10 a. Further, since the iron piece 4 is biased by the hinge spring 24, the iron piece 4 moves away from the iron core 5 with the demagnetization of the electromagnet portion 10a. The card 23 operates in conjunction with the operation of the iron piece 4 accompanying such excitation and demagnetization of the electromagnet portion 10a. The contact 9 opens and closes in conjunction with the operation of the card 23.

  The present invention is not limited to the above-described embodiments, and various modifications are possible within the scope shown in the claims, and embodiments obtained by appropriately combining technical means disclosed in different embodiments. Is also included in the technical scope of the present invention.

  Examples of the present invention will be described below, but the present invention is not limited to these examples without departing from the spirit of the present invention. In the present embodiment, the maximum value of the element A content described above may be referred to as “surface A concentration”. For example, the maximum value of the chromium content contained in the alloy layer may be referred to as “surface chromium concentration”. In addition, the said element is distributed so that it may decrease gradually toward the inner side from the surface of the said iron-type components. In the following, the unit of concentration is sometimes referred to as “%”, which means “% by weight”.

[Examples 1 to 5 and Comparative Examples 1 to 3]
Manufacture of 1.5mm thick, 15mm wide, 28mm long yoke, and 45mm outer diameter, 33mm inner diameter, 1.2mm thick ring using 0.01% by weight electromagnetic soft iron (SUYP) did. FIG. 8 is a schematic view showing the appearance of the ring. In FIG. 8A, D indicates the outer diameter of the ring 11, and d indicates the inner diameter of the ring 11. FIG. 8B is a diagram viewed from the x-axis direction of FIG. “T” in FIG. 8B indicates the thickness of the ring 11.

  In Examples 1 to 5 and Comparative Examples 1 and 2, the above-described yoke and ring were subjected to diffusion penetration treatment under different temperature conditions, and test pieces were produced. The diffusion and permeation treatment is carried out by embedding a yoke and a ring in a penetrant prepared by mixing 40 to 80% by weight of chromium powder, 19.5 to 59.5% by weight of alumina powder and 0.5% by weight of ammonium chloride powder, and semi-sealing. Filling the container and flowing hydrogen gas, 700 ° C. (Comparative Example 1), 750 ° C. (Example 1), 800 ° C. (Example 2), 850 ° C. (Example 3), 900 ° C. (Example 4), This was performed by heating at 950 ° C. (Example 5) or 1000 ° C. (Comparative Example 2) for 10 hours. In Comparative Example 3, a yoke and a ring plated with Ni were used as test pieces. Using the yoke, the thickness of the alloy layer, the concentration of the element that diffused and penetrated, the corrosion resistance, the wear resistance, and the suction force were investigated, and the quality improvement effect of the parts by the diffusion and penetration treatment was confirmed. Further, a coercive force test was performed using the ring.

<Thickness of alloy layer, concentration of element diffused and penetrated>
The thickness of the alloy layer was measured by cutting the yoke and observing its cross section. The thickness of the alloy layer was measured at 10 locations, and the average was obtained. The surface chromium concentration was measured by surface element analysis by SEM and element concentration analysis by EPMA.

<Alloy layer surface hardness>
Vickers hardness was measured as the surface hardness of the alloy layer. Vickers hardness was calculated based on JIS Z 2244 (1992). In this experiment, the test was performed with a test load of 25 gf.

<Corrosion resistance test (salt spray test)>
As a corrosion resistance test, a salt spray test was performed to determine the ratio of the corrosion area on the surface of the test piece. In a salt spray test tank maintained at 35 ° C., salt water having a salt concentration of 5 ± 1% (mass ratio) and a pH value of 6.5 to 7.2 (water temperature 20 ± 2 ° C.) was continuously added to the test piece. Spraying for a period of time and then leaving it in the test tank for 20 to 22 hours was taken as one cycle, and this was performed for 3 cycles. The test was performed based on JIS C 0024 (2000) (IEC 60068-2-52 (1996)) and JIS C 5442 (1996).

<Abrasion resistance test>
The test piece was actually installed in a relay, the appearance of the surface state of the metal wear part after opening and closing 20 million times was confirmed, and the magnitude of wear was determined by the degree of wear powder generation. The opening / closing frequency was 1800 times / minute. The test was performed based on JIS C 4530 (1996), JIS C 5442 (1996), and NECA C 5440 (1999).

<Suction force test>
FIG. 9 shows an apparatus for the suction force test. A relay is manufactured using the yoke 3, the iron piece 4 and the iron core 5, which are test pieces, and a rated current is supplied to the coil 14 wound around the iron core 5 by an external power source. The load cell 16 is used to generate the relay 15 The suction force to be measured was measured.

<Coercivity test>
The coercive force of the test piece processed as a circular ring was measured. FIG. 10 shows a method of winding a coil around a test piece. First, the test piece 11 (FIG. 10A) is covered with the insulating tape 17a (FIG. 10B). Next, an insulated conductor is uniformly wound around the test piece 11 as the magnetic flux detecting coil 18 (FIG. 10C). Thereafter, the test piece 11 is further covered with an insulating tape 17b (FIG. 10D). On the insulating tape 17b, as an exciting coil 19, one layer of an insulated conductor capable of flowing the maximum magnetization current at the time of measurement has a sufficient number of turns to obtain the maximum magnetic field strength. Alternatively, multi-layer winding is performed (FIG. 10E). FIG. 10F is a schematic view showing the appearance of a test piece wound with a coil, and FIG. 10G shows a cross-sectional view taken along line AA ′ of FIG. In this test, 100T was adopted as the magnetic flux density of the magnetic flux detecting coil, and 200T was adopted as the magnetic flux density of the exciting coil.

  The coercive force is the strength of a magnetic field in the opposite direction necessary to return a magnetized magnetic body to an unmagnetized state. The smaller the coercivity value, the better the magnetic properties. The coercive force was measured with a BH curve tracer. The coercive force value was read from the measured BH curve. FIG. 11 shows an example of a BH curve. The measurement was based on the measurement of the initial magnetization curve. In addition, demagnetization was reliably performed for each measurement. The test was performed based on JIS C 2504 (2000).

<Results of Examples 1 to 5 and Comparative Examples 1 to 3>
The results of Examples 1 to 5 and Comparative Examples 1 to 3 are shown in Table 1. The result of the abrasion resistance test is shown as a ratio of the amount of abrasion powder generated in each of the examples and the comparative example when the amount of abrasion powder generated in Comparative Example 3 (Ni plated product) is 100%. It can be said that the smaller the numerical value of the amount of generated abrasion powder, the better the wear resistance. The result of the suction force test is shown as a ratio of the suction force of each example and the comparative example when the suction force of the comparative example 3 is 100%.

(Result of alloy layer surface hardness)
The alloy layer of chromium and iron was harder than electromagnetic soft iron (Vickers hardness: 90 to 150 mHv) as a base material, and as shown in Table 1, it exhibited a Vickers hardness of 160 to 630 mHv. Comparative Example 1 had a Vickers hardness of 160 mHv, which was inferior to Comparative Example 3. In Comparative Example 1, the alloy layer was also as thin as 3 μm.

(Results of corrosion resistance test)
The corrosion area of Comparative Example 3 which is a Ni-plated product was 40 to 50%, whereas Comparative Example 1 had a bad result of 50 to 60%, but Examples 1 to 5 were all Comparative Example 3. Less corrosion than. In particular, Examples 3 to 5 (alloy layer thickness: 20 to 60 μm, chromium concentration: 37 to 61% by weight) did not corrode at all. From the above, it is considered that the thicker the alloy layer and the higher the chromium concentration, the better the corrosion resistance. In addition, even when Cr, which is an antiferromagnetic material, is used instead of Ni, which is a ferromagnetic material, the corrosion resistance can be improved without losing magnetic properties by controlling the thickness of the alloy layer. Was found to be possible.

(Results of wear resistance test)
Although the wear resistance of Comparative Example 1 is inferior to that of Comparative Example 3 which is a Ni-plated product, the results of Examples 1 to 5 and Comparative Example 2 are the same as or higher than those of Comparative Example 3. It was. In Examples 3 to 5 where the Vickers hardness was particularly high, there was almost no wear.

(Result of suction test)
Since chromium is an antiferromagnetic material, it was expected that the magnetic properties would be deteriorated by forming an alloy layer. However, as shown in Comparative Examples 1-2 and Examples 1-5 in Table 1, the alloy When the thickness of the layer was 60 μm or less, a suction force equal to or greater than that of Comparative Example 3 or Comparative Example 3 was obtained. However, in Comparative Example 2 (alloy layer thickness: 80 μm), it was found that the attractive force was reduced and it could not be used as a magnetic component.

  FIG. 12 shows the relationship between the stroke ST (mm) and the suction force F. The suction force of Example 4 (treatment temperature: 900 ° C.) and Comparative Example 3 are equivalent. It can be seen that the suction force decreases as the processing temperature increases, and the suction force increases as the processing temperature decreases.

(Results of coercive force test)
Also in the coercive force test, as shown in Comparative Example 1 and Examples 1 to 5 in Table 1, if the thickness of the alloy layer is 60 μm or less, the coercive force equal to or greater than that of Comparative Example 3 or Comparative Example 3 is obtained. Obtained. In addition, if it was +10 A / m or less compared with the comparative example 3 which is Ni plating goods, it was judged that it could be used as a magnetic component. However, in Comparative Example 2 (alloy layer thickness: 80 μm), it was found that the coercive force was lowered and it could not be used as a magnetic component.

In addition, in the combination of the heating temperature (800 to 900 ° C.) and the heating time (15 to 30 minutes) for improving the magnetic properties conventionally performed by Ni plating or the like, the crystal grain size of the base material is JIS G0551 ( The ferrite crystal grain size number defined in 2005) is 2 or more (the number of crystal grains per 1 mm ^{2 in} cross-sectional area is about 32 or less, see FIG. 13A). On the other hand, in Examples 1-5, since the heating temperature is 750-950 ° C. and the heating time is significantly long as 10 hours, the coarsening of the crystal grains is progressing, and the ferrite grain size number is Becomes −1 or less (the number of crystal grains per 1 mm ^{2 in} cross-sectional area is about 4 or less, see FIG. 13B). FIGS. 13C and 13D are diagrams in which the crystal grain boundaries in FIGS. 13A and 13B are made obvious.

  From the above, when the thickness of the alloy layer is 60 μm or less (Examples 1 to 5 and Comparative Example 1), good magnetic properties are obtained when the ferrite crystal grain size number is −1 or less. it is conceivable that. However, when the thickness of the alloy layer reaches 80 μm (Comparative Example 2), even if diffusion penetration treatment is performed under the heating condition in which the crystal grains of the base material are coarsened at 1000 ° C. × 10 hours, the magnetic properties are deteriorated. Was inevitable.

[Examples 1-5 and Comparative Examples 1-6]
NSSMAG1 (soft magnetic stainless steel) (Comparative Examples 4 to 5) and SUYP (electromagnetic soft iron) (Comparative Example 6) were also subjected to the above-described coercive force test, and SUYP (Examples 1 to 5 and comparison) in which chromium was diffused and infiltrated. The results were compared with the results obtained using Examples 1-2) and Ni-plated SUYP (Comparative Example 3). The test results are shown in Table 2.

  As shown in Table 2, Comparative Example 3 with Ni plating had a larger coercive force value than Comparative Example 6 without Ni plating. Moreover, in Examples 1 and 2 among the examples subjected to the diffusion and penetration treatment of chromium, the coercive force was excellent as compared with Comparative Examples 4 to 5 in which chromium was uniformly contained.

Example 6
Yoke (maximum length 22 mm in the z-axis direction in FIG. 4, maximum length 11 mm in the x-axis direction, width (y-axis direction) in FIG. Length) 11.5 mm) was subjected to diffusion penetration treatment under the following conditions.
Composition of penetrant: chromium powder (40% by weight), alumina powder (59.5% by weight), ammonium chloride powder (0.5% by weight)
Processing temperature: 800 ° C
Treatment time: 5 hours As a result, a yoke having an alloy layer thickness of 15 μm and a surface chromium concentration of 30% was obtained. FIG. 14A shows the chromium concentration analysis value of the alloy layer cross section by the EPMA analyzer.

  The obtained yoke was subjected to the same magnetic property test (attraction force test and coercive force test), corrosion resistance test and wear resistance test as in Example 1. The magnetic properties were as good as the current Ni-plated product (Comparative Example 3). In the corrosion resistance test, the corrosion area was 10 to 20%, which was reduced compared with Comparative Example 3 (40 to 50%), and the effect of the present invention was confirmed. In the abrasion resistance test, the obtained yoke was incorporated in a relay and subjected to an opening / closing test 20 million times. As a result, the sliding surface of the yoke was hardly worn and was good.

Example 7
Yoke (maximum length 22 mm in the z-axis direction in FIG. 4, maximum length 11 mm in the x-axis direction, width (y-axis direction) in FIG. Length) 11.5 mm) was subjected to diffusion penetration treatment under the following conditions.
Composition of penetrant: ferrovanadium powder (50 wt%), alumina powder (49.5 wt%), ammonium chloride powder (0.5 wt%)
Processing temperature: 930 ° C
Treatment time: 5 hours As a result, a yoke having a thickness of 20 μm and a surface vanadium concentration of 49% was obtained. FIG. 14 (b) shows the vanadium concentration analysis value of the alloy layer cross section by the EPMA analyzer.

  The obtained yoke was subjected to the same magnetic property test, corrosion resistance test, and wear resistance test as in Example 1. The magnetic characteristics were as good as in Comparative Example 3. In the corrosion resistance test, it was not corroded at all and showed much better corrosion resistance than Comparative Example 3 (40-50%), confirming the effect of the present invention. In the abrasion resistance test, the obtained yoke was incorporated in a relay and subjected to an opening / closing test of 20 million times. As a result, the sliding surface of the yoke was hardly worn and showed excellent abrasion resistance.

Example 8
Yoke (maximum length 22 mm in the z-axis direction in FIG. 4, maximum length 11 mm in the x-axis direction, width (y-axis direction) in FIG. Length) 11.5 mm) was subjected to diffusion penetration treatment under the following conditions.
Composition of penetrant: iron-aluminum alloy powder (65 wt%), alumina powder (34.5 wt%), ammonium chloride powder (0.5 wt%)
Processing temperature: 830 ° C
Treatment time: 5 hours As a result, a yoke having a thickness of 30 μm and a surface aluminum concentration of 33% was obtained. FIG. 14C shows the aluminum concentration analysis value of the alloy layer cross section by the EPMA analyzer.

  The obtained yoke was subjected to the same magnetic property test, corrosion resistance test, and wear resistance test as in Example 1. The magnetic characteristics were as good as in Comparative Example 3. In the corrosion resistance test, it was not corroded at all and showed much better corrosion resistance than Comparative Example 3 (40-50%), confirming the effect of the present invention. In the abrasion resistance test, the obtained yoke was incorporated in a relay and subjected to an opening / closing test of 20 million times. As a result, the sliding surface of the yoke was hardly worn and showed excellent abrasion resistance.

Example 9
Yoke (maximum length 22 mm in the z-axis direction in FIG. 4, maximum length 11 mm in the x-axis direction, width (y-axis direction) in FIG. Length) 11.5 mm) was subjected to diffusion penetration treatment under the following conditions.
Composition of penetrant: chromium powder (40% by weight), alumina powder (59.5% by weight), ammonium chloride powder (0.5% by weight)
Processing temperature: 800 ° C
Treatment time: 13 hours As a result, a yoke having an alloy layer thickness of 15 μm, a surface hardness of 270 mHv, and a surface chromium concentration of 33% was obtained. FIG. 15A shows the chromium concentration analysis value of the alloy layer cross section by the EPMA analyzer.

  The obtained yoke was subjected to the same magnetic property test (attraction force test and coercive force test), corrosion resistance test and wear resistance test as in Example 1. The magnetic properties were as good as the current Ni-plated product (Comparative Example 3). In the corrosion resistance test, the corrosion area was 10 to 20%, which was reduced compared with Comparative Example 3 (40 to 50%), and the effect of the present invention was confirmed. In the abrasion resistance test, the obtained yoke was incorporated in a relay and subjected to an opening / closing test 20 million times. As a result, the sliding surface of the yoke was hardly worn and was good.

Example 10
Iron pieces processed using low carbon steel (SPCC, carbon content 0.12 wt%) (maximum length 13.5 mm in the x-axis direction in FIG. 4, maximum length 8.5 mm in the z-axis direction, width ( The diffusion permeation treatment was applied to the length in the y-axis direction (11.5 mm) under the following conditions.
Composition of penetrant: chromium powder (40% by weight), alumina powder (59.5% by weight), ammonium chloride powder (0.5% by weight)
Processing temperature: 880 ° C
Treatment time: 8 hours As a result, an iron piece having an alloy layer thickness of 29 μm, a surface hardness of 310 mHv, and a surface chromium concentration of 42% was obtained. FIG. 15B shows the chromium concentration analysis value of the alloy layer cross section by the EPMA analyzer.

  The obtained iron pieces were subjected to the same magnetic property test (attraction force test and coercive force test), corrosion resistance test and wear resistance test as in Example 1. The magnetic properties were as good as the current Ni-plated product (Comparative Example 3). In the corrosion resistance test, the surface was not corroded at all, showing much better corrosion resistance than Comparative Example 3 (40 to 50%), and the effect of the present invention could be confirmed. In the wear resistance test, the obtained iron piece was incorporated in a relay and subjected to an opening / closing test 20 million times. As a result, the sliding surface of the iron piece was hardly worn and showed excellent wear resistance.

Example 11
An iron core (diameter 7 mm, length 20.5 mm) processed using low carbon steel (SPCC, carbon content 0.07 wt%) was subjected to diffusion penetration treatment under the following conditions.
Composition of penetrant: chromium powder (40% by weight), alumina powder (59.5% by weight), ammonium chloride powder (0.5% by weight)
Processing temperature: 930 ° C
Treatment time: 6 hours As a result, an iron core having an alloy layer thickness of 38 μm, a surface hardness of 360 mHv, and a surface chromium concentration of 49% was obtained. FIG. 15C shows the chromium concentration analysis value of the alloy layer cross section by the EPMA analyzer.

  The obtained iron core was subjected to the same magnetic property test (attraction force test and coercive force test), corrosion resistance test and wear resistance test as in Example 1. The magnetic properties were as good as the current Ni-plated product (Comparative Example 3). In the corrosion resistance test, the corrosion area was 10 to 20%, which was far superior to that of Comparative Example 3 (40 to 50%), indicating the effect of the present invention. In the wear resistance test, the obtained iron core was incorporated into a relay and subjected to an opening / closing test 20 million times. As a result, the sliding surface of the iron core was hardly worn and showed excellent wear resistance.

Example 12
An iron core (diameter: 7 mm, length: 20.5 mm) processed using low-carbon steel (SPCC, carbon content 0.01% by weight) was subjected to diffusion penetration treatment under the following conditions.
Composition of penetrant: ferrovanadium powder (50 wt%), alumina powder (49.5 wt%), ammonium chloride powder (0.5 wt%)
Processing temperature: 930 ° C
Treatment time: 7 hours As a result, a yoke having a thickness of 16 μm, a surface hardness of 410 mHv, and a surface vanadium concentration of 43% was obtained. FIG. 15 (d) shows the vanadium concentration analysis value of the alloy layer cross section by the EPMA analyzer.

  The obtained iron core was subjected to the same magnetic property test, corrosion resistance test, and wear resistance test as in Example 1. The magnetic characteristics were as good as in Comparative Example 3. In the corrosion resistance test, it was not corroded at all and showed much better corrosion resistance than Comparative Example 3 (40-50%), confirming the effect of the present invention. In the wear resistance test, the obtained iron core was incorporated into a relay and subjected to an opening / closing test 20 million times. As a result, the sliding surface of the iron core was hardly worn and showed excellent wear resistance.

Example 13
Iron pieces machined using low carbon steel (SPCC, carbon content 0.10% by weight) (maximum length 13.5 mm in the x-axis direction in FIG. 4, maximum length 8.5 mm in the z-axis direction, width ( The diffusion permeation treatment was applied to the length in the y-axis direction (11.5 mm) under the following conditions.
Composition of penetrant: iron-aluminum alloy powder (65 wt%), alumina powder (34.5 wt%), ammonium chloride powder (0.5 wt%)
Processing temperature: 800 ° C
Treatment time: 5 hours As a result, an iron piece having a thickness of 31 μm, a surface hardness of 250 mHv, and a surface aluminum concentration of 29% was obtained. FIG. 15E shows the aluminum concentration analysis value of the alloy layer cross section by the EPMA analyzer.

  The obtained iron piece was subjected to the same magnetic property test, corrosion resistance test and wear resistance test as in Example 1. The magnetic characteristics were as good as in Comparative Example 3. In the corrosion resistance test, it was not corroded at all and showed much better corrosion resistance than Comparative Example 3 (40-50%), confirming the effect of the present invention. In the wear resistance test, the obtained iron piece was incorporated in a relay and subjected to an opening / closing test 20 million times. As a result, the sliding surface of the iron piece was hardly worn and showed excellent wear resistance.

  From Examples 6 to 13, even when Cr, V, or Al, which is an antiferromagnetic material, a diamagnetic material, or a paramagnetic material, is used instead of Ni that is a ferromagnetic material, the thickness of the alloy layer It was found that by controlling the thickness, the corrosion resistance can be improved without losing the magnetic properties.

[Examples 14 to 15 and Comparative Examples 7 to 10]
The metal structure was observed about the test piece processed using SPCC. In Example 14 and Comparative Examples 7-8, a test piece having a thickness of 1.2 mm was used, and in Example 15 and Comparative Examples 9-10, a test piece having a thickness of 1.6 mm was used. In Examples 14 to 15, a penetrant (chromium powder (40 wt%), alumina powder (59.5 wt%), ammonium chloride powder (0.5 wt%)) was used, and the treatment temperature was 840 ° C. The treatment was performed for 9 hours to form an alloy layer. In Comparative Examples 7 and 9, no heat treatment was performed, and in Comparative Examples 8 and 10, a heat treatment at 850 ° C. was performed. In Comparative Examples 7 to 10, no diffusion permeation treatment and Ni plating were performed.

  16-19 has shown sectional drawing of a different magnification about Example 14 and Comparative Examples 7-8. 20-23 has shown sectional drawing of a different magnification about Example 15 and Comparative Examples 9-10. 16-23, in Examples 14-15, it turns out that the metal structure has grown compared with Comparative Examples 7-10.

[Examples 16 to 19 and Comparative Example 11]
A salt spray test was performed on the yoke processed using pure iron in the same manner as in Example 1. Examples 16 to 19 use a penetrant (chromium powder (40% by weight), alumina powder (59.5% by weight), ammonium chloride powder (0.5% by weight)) with a treatment time of 8 hours. This is a yoke in which chromium is diffused and penetrated. The processing temperature was 765 ° C. in Example 16, 800 ° C. in Example 17, 850 ° C. in Example 18, and 950 ° C. in Example 19. Comparative Example 11 is a yoke plated with Ni. In each example and comparative example, three yokes were produced.

  The test results are shown in FIGS. 24 to 28 show photographs seen from both sides of the yoke. That is, the photograph seen from both x-axis directions in FIG. FIG. 24 shows the results of Comparative Example 11, and FIGS. 25 to 28 show the results of Examples 16-19. In Examples 16-19, it turns out that a corrosion area is few compared with the comparative example 11.

[Example 20 and Comparative Example 12]
Corrosion resistance to nitric acid was examined for iron pieces and yokes processed using SPCC. In Example 20, a penetrant (chromium powder (40% by weight), alumina powder (59.5% by weight), ammonium chloride powder (0.5% by weight)) was used, and the processing temperature was 860 ° C. and the processing time. An iron piece and a yoke in which chromium was diffused and penetrated in 9 hours were used, and in Comparative Example 12, an iron piece and a yoke subjected to Ni plating were used. An iron piece and a yoke are incorporated in the relay, and arc heat is generated by opening and closing the contacts, and nitric acid gas is generated inside the relay by the arc heat.

  The test results are shown in FIG. In Comparative Example 12 (FIGS. 29A and 29B), patina is generated, whereas in Example 20 (FIGS. 29C and 29D), patina is hardly seen.

  INDUSTRIAL APPLICABILITY The present invention can be used particularly in a method for manufacturing a magnetic component that is required to have wear resistance, corrosion resistance, and magnetic characteristics in electronic components such as relays and switches.

DESCRIPTION OF SYMBOLS 1 Iron system component 2 Powder containing one or more elements selected from the group consisting of Cr, V, Ti, Al, and Si 3 Yoke (magnetic component)
4 Iron pieces (magnetic parts)
5 Iron core (magnetic parts)
10 Electromagnet device 100 Relay (electronic component)

Claims (8)

A method of manufacturing a magnetic component comprising an iron-based component obtained by processing an iron-based material,
An alloy layer forming step of forming an alloy layer by performing a process of diffusing and penetrating one or more elements selected from the group consisting of Cr, V, Ti, Al, and Si into the iron-based component,
The treatment for diffusing and penetrating the element is selected from the group consisting of Cr, V, Ti, Al, and Si at a treatment time of 5 hours to 15 hours and a treatment temperature of 750 ° C. to 950 ° C. It is performed by embedding the iron-based component in a powder containing one or more elements ,
The sum of the maximum values of the content of one or more elements selected from the group consisting of Cr, V, Ti, Al, and Si at any plurality of positions in the alloy layer is 20 wt% or more and 65 wt% or less. A method for producing a magnetic component, comprising:   2. The method of manufacturing a magnetic component according to claim 1, wherein the treatment time is 8 hours or more and 10 hours or less.   The method for manufacturing a magnetic component according to claim 1 or 2, wherein the iron-based material has a carbon content of 0 wt% or more and 0.15 wt% or less.   The method for producing a magnetic component according to any one of claims 1 to 3, wherein the iron-based material has a carbon content of 0 wt% or more and less than 0.05 wt%.   In the alloy layer forming step, the crystal grains of the iron-based component are grown until the ferrite crystal grain size number 1 or less specified in JIS G0551 (2005) is reached. The manufacturing method of the magnetic component of description. Process for cementation of the above elements, the method of manufacturing a magnetic component according to any one of claims 1 to 5, characterized in that is carried out while supplying hydrogen gas. The method of manufacturing a magnetic part according to any one of claims 1 to 6 , wherein the magnetic part has a Vickers hardness measured in accordance with JIS Z 2244 (1992) of 190 to 450 mHv. The magnetic force according to any one of claims 1 to 7 , wherein the magnetic component has a coercive force measured in accordance with JIS C 2504 (2000) of 30.5 to 45.5 A / m. A manufacturing method for parts.