JP7158807B2 - 焼結磁石の製造方法および焼結磁石 - Google Patents
焼結磁石の製造方法および焼結磁石 Download PDFInfo
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Description
本出願は、2019年9月26日付韓国特許出願第10-2019-0118839号および2020年9月23日付韓国特許出願第10-2020-0122724号に基づいた優先権の利益を主張し、当該韓国特許出願の文献に開示された全ての内容は本明細書の一部として組み含まれる。
前記金属箔は、MoまたはTaであり得る。
Nd2.4Fe12.8BCu0.05の組成で合成された磁石粉末と焼結剤を乳鉢で混合し、所望する形状の磁石を得るための型枠としてモリブデン(Mo)ルツボ(crucible)またはカーボン(C)ルツボに入れる。その後、ほぼ10-6Torr以下の超高真空状態で昇温速度摂氏300度/時間で摂氏850度に上げた後、30分程度維持することができる。再び同じ昇温速度で摂氏1070度に昇温して2時間維持した後、常温で自然冷却して焼結体(焼結以降の物質)を得ることができる。焼結する過程で焼結剤として、NdH2を6wt%添加した。すべての作業はアルゴン(Ar)雰囲気下で進行した。
比較例1と大部分同一の条件で焼結したが、焼結する過程で焼結剤として、NdH2粉末6wt%、Al粉末0.17wt%およびCu粉末0.2wt%添加した。
実施例1と大部分同一の条件で焼結したが、焼結する過程で焼結剤として、NdH2とNd0.7Al0.2Cu0.1の金属合金粉末を実施例1と同量になるように添加した。言い換えると、実施例1、2で磁石粉末と焼結剤の混合物を焼結時、追加した各金属元素の原子量比率が磁石粉末質量に対して同一であり得る。
比較例1と大部分同一の条件で焼結したが、Nd2.4Fe12.8BCu0.05の組成で合成された磁石粉末の代わりにNd2.4Fe12Co0.8BCu0.05の組成で合成された磁石粉末を使用した。また、焼結剤として、NdH2を10wt%添加した。
比較例2と大部分同一の条件で焼結したが、焼結する過程で焼結剤として、NdH2粉末10wt%、Al粉末0.17wt%およびCu粉末0.2wt%添加した。
実施例3と大部分同一の条件で焼結したが、焼結する過程で焼結剤として、NdH2とNd0.7Al0.2Cu0.1の合金粉末を実施例3と同量になるように添加した。NdH2とNd0.7Al0.2Cu0.1の金属合金粉末を製造するために、次のような焼結剤製造方法を使用した。NdH2粉末、Al粉末、およびCu粉末を混合し、冷間静水圧成形法(Cold Isostatic Pressing、CIP)で前記混合物を凝集させる。その後、Mo金属箔やTa金属箔に凝集された混合物を囲んでアルゴン(Ar)ガス雰囲気で時間当たり摂氏300度に昇温して摂氏900度~摂氏1050度で追加1時間加熱する。製造された金属合金を粉砕して粉末の形態で得る。
実施例4と大部分同一の条件で焼結したが、焼結剤としてNdH2とNd0.7Al0.2Cu0.1の合金粉末の代わりにNdH2とDy0.7Al0.2Cu0.1の合金粉末を使用した。
実施例4と大部分同一の条件で焼結したが、焼結剤としてNdH2とNd0.7Al0.2Cu0.1の合金粉末の代わりにNdH2とPr0.7Al0.2Cu0.1の合金粉末を使用した。
図2は、比較例1、実施例1および実施例2でそれぞれ測定した保磁力(X軸)による磁束密度(Y軸)を示す。図2を参照すると、比較例1に比べて実施例1、2で焼結磁石特性が向上することを確認できる。また、金属合金の粉末を焼結剤として使用して焼結した場合(実施例2)が、それぞれの焼結成分元素に該当する物質の粉末を混合して焼結した場合(実施例1)より焼結磁石特性が向上することを確認できる。実施例1に比べて実施例2の保磁力増加量を百分率で換算すればほぼ10~20%程度向上することを確認できる。言い換えると、焼結剤の形態変更により保磁力の有意義な増加量を得ることができる。
比較例1と大部分同一の条件で焼結して焼結磁石を形成し、その後、Pr0.7Al0.2Cu0.1Ga0.1の金属合金粉末を溶浸処理(infiltration)のための助剤として使用した。
実施例7と大部分同一の条件で焼結したが、Pr0.7Al0.2Cu0.1Ga0.1の合金粉末の代わりにDy0.7Al0.2Cu0.1Ga0.1の合金粉末を溶浸処理のための助剤として使用した。
図5および図6は、焼結磁石に溶浸処理のための助剤として4相金属合金粉末の使用前後に測定した保磁力(X軸)による磁束密度(Y軸)を示すグラフである。図5で、実施例7のPr0.7Al0.2Cu0.1Ga0.1の金属合金粉末を使用して溶浸処理した磁石に対する保磁力水準を確認するために、焼結磁石に対して2wt%のPr0.7Al0.2Cu0.1Ga0.1の合金粉末を焼結磁石に付着した状態で、高真空下で摂氏900度でほぼ10時間溶浸(infiltration)を行い、ほぼ摂氏520度で後熱処理を行った結果前後の保磁力を示す。図6では、実施例8のDy0.7Al0.2Cu0.1Ga0.1の金属合金粉末を使用して溶浸処理した磁石に対する保磁力水準を示す。
200:チューブファーネス
Claims (8)
- 還元-拡散法でR-Fe-B系磁石粉末を製造する段階、
前記R-Fe-B系磁石粉末に焼結剤としてR-Al-Cu粉末を添加して混合粉末を形成する段階、および
前記混合粉末を焼結して焼結磁石を形成する段階を含み、
前記R-Al-Cu粉末は、R、AlおよびCuの合金であり、前記Rは、Nd、Pr、Dy、TbまたはCeであり、
前記焼結剤としてR-Al-Cu粉末を形成する段階をさらに含み、
前記R-Al-Cu粉末を形成する段階は、
RH 2 粉末、Al粉末、およびCu粉末を混合して焼結前駆体を形成する段階、
前記焼結前駆体を凝集させる段階、
前記凝集された焼結前駆体を昇温して金属合金を形成する段階、および
前記金属合金を粉砕して前記焼結剤を形成する段階を含む、焼結磁石の製造方法。 - 前記凝集された焼結前駆体を昇温する時、前記焼結前駆体を金属箔で包む段階をさらに含む、請求項1に記載の焼結磁石の製造方法。
- 前記焼結前駆体を形成する段階は、液状のGaを混合する段階をさらに含む、請求項2に記載の焼結磁石の製造方法。
- 前記金属箔は、MoまたはTaである、請求項2または3に記載の焼結磁石の製造方法。
- 前記凝集された焼結前駆体を前記金属箔で包んで昇温する時、アルゴンガス雰囲気下で昇温する、請求項4に記載の焼結磁石の製造方法。
- 前記金属合金を形成する段階は、前記凝集された焼結前駆体を金属箔で包んで摂氏900度~摂氏1050度まで昇温させた後、追加熱処理する段階をさらに含む、請求項1に記載の焼結磁石の製造方法。
- 前記焼結前駆体を凝集させる段階は、油圧プレス、タッピングおよび冷間静水圧成形法(Cold Isostatic Pressing、CIP)のうちのいずれか一つの加圧法を使用する、請求項1から6のいずれか一項に記載の焼結磁石の製造方法。
- 前記焼結剤として、前記R-Al-Cu粉末にNdH2粉末を追加する段階をさらに含む、請求項1から7のいずれか一項に記載の焼結磁石の製造方法。
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KR10-2019-0118839 | 2019-09-26 | ||
KR20190118839 | 2019-09-26 | ||
KR1020200122724A KR102589893B1 (ko) | 2019-09-26 | 2020-09-23 | 소결 자석의 제조 방법 및 소결 자석 |
KR10-2020-0122724 | 2020-09-23 | ||
PCT/KR2020/012913 WO2021060849A1 (ko) | 2019-09-26 | 2020-09-24 | 소결 자석의 제조 방법 및 소결 자석 |
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