JPWO2010082492A1 - R−t−b系焼結磁石の製造方法 - Google Patents
R−t−b系焼結磁石の製造方法 Download PDFInfo
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Abstract
Description
本発明では、R−T−B系合金Aの粉末とR−T−B系合金Bの粉末とを混合した粉末からR−T−B系焼結磁石を製造する。
本発明では、前記R−T−B系合金Aと、前記R−T−B系合金Bとを、粉砕することにより、それぞれ、所定の粉末粒径を有する粉末を作製する。相対的に重希土類元素RHの含有量の少ないR−T−B系合金Aの粉末の粒径D50は、R−T−B系合金Bの粉末の粒径D50よりも1.0μm以上大きくする。この粒径差が1.0μm未満であると、焼結時の各粉末の挙動を制御できず、焼結後の主相外殻部近傍に重希土類元素が濃化した組織を生成することができない。なお、D50とは、気流分散型レーザー回折法により得られる粉末粒径(粒径の小さいものから順に並べていったときに累積の体積が全体の50%になったときの粒子の直径)の値である。
原料合金は、通常のインゴット鋳造法、ストリップキャスト法、直接還元法などの方法で得ることができる。
本発明の磁石を得るための製造方法の一例として、粗粉砕と微粉砕の2段階の粉砕を行う場合を以下に示す。以下の記載は、他の製造方法を排除するものではない。
本実施形態では、前記粉砕方法で作製されたR−T−B系合金粉末AとR−T−B系合金粉末Bとを、例えばロッキングミキサー内で、潤滑剤を適量添加・混合し、潤滑剤で合金粉末粒子の表面を被覆する。R−T−B系合金粉末AとR−T−B系合金粉末Bは、質量比でR−T−B系合金粉末A:R−T−B系合金粉末B=60:40から90:10になるように混合する。
本発明の成形方法は、既知の方法を用いることができる。例えば、磁界中で前記微粉砕粉を、金型を用いて加圧成形する方法である。酸素や炭素などの不純物の取り込みを最小限とするため、潤滑剤等の使用は最小限にとどめることが望ましい。潤滑剤を用いる際は、焼結工程、またはその前に脱脂可能な、揮発性の高い潤滑剤を、公知のものから選択して用いてもよい。
焼結過程における雰囲気は、真空中または大気圧以下の不活性ガス雰囲気とする。ここでの不活性ガスとは、Ar及びまたはHeガスを指す。
焼結工程終了後、一旦300℃以下にまで冷却した後、再度400℃以上、焼結温度以下の範囲で熱処理を行い、保磁力を高めることができる。この熱処理は、同一温度、または温度を変えて複数回行ってもよい。特に、本発明においては、Cu量を所定範囲とすることで、より顕著に熱処理による保磁力向上を図ることができ、例えば1000℃で1時間熱処理後急冷し、続いて800℃で1時間熱処理後急冷、500℃で1時間熱処理後急冷というように、3段階の熱処理を行うこともできる。また、熱処理温度で保持後、徐冷することで保磁力が向上する場合もある。焼結後の熱処理では、通常は磁化が変化することはないので、磁石組成、大きさ、寸法形状毎に、保磁力向上のために適正な条件を選択することができる。
本発明のR−T−B系焼結磁石には、所望の形状、寸法を得るため、一般的な切断、研削等の機械加工を施すことができる。
本発明のR−T−B系焼結磁石には、好ましくは防錆のための表面コーティング処理を施す。例えば、Niめっき、Snめっき、Znめっき、Al蒸着膜、Al系合金蒸着膜、樹脂塗装などを行うことができる。
本発明のR−T−B系焼結磁石には、一般的な着磁方法で着磁することができる。例えば、パルス磁界を印加する方法や、静的な磁界を印加する方法が適用できる。なお、焼結磁石の着磁は、取り扱い上の容易さを考慮して、通常は磁気回路を組み立てた後、前記方法で着磁するが、もちろん磁石単体で着磁することもできる。
純度99.5質量%以上のNd、純度99.9質量%以上のTb、Dy、電解鉄、低炭素フェロボロン合金を主として、その他目的元素を純金属またはFeとの合金の形で添加して目的組成の合金を溶解し、ストリップキャスト法で鋳造し、厚さ0.3mmから0.4mmの板状合金を得た。
実施例1と同様に乾式粉砕にて表4に示す組成と粒径D50を有する、R−T−B系合金粉末AとR−T−B系合金粉末Bとを作製した。
実施例1と同様に乾式粉砕にて、表7に示す組成と粒径D50を有する、R−T−B系合金粉末AとR−T−B系合金粉末Bとを作製した。
2 希土類元素R中に重希土類元素RHが相対的に多いR2T14B系合金粉末
3 希土類元素R中に重希土類元素RHが相対的に少ない領域
4 希土類元素R中に重希土類元素RHが相対的に多い領域
5 R−T−B系焼結磁石のR2T14B主相結晶粒子
Claims (4)
- R(Rは、希土類元素の少なくとも1種)が27.3質量%以上31.2質量%以下、Bが0.92質量%以上1.15質量%以下、Tが残部(ここでTはFeまたはFeとCoであり、FeとCoの場合CoはTのうち20質量%以下)である組成で表されるR−T−B系合金粉末Aと
R(Rは希土類元素の少なくとも1種)が27.3質量%以上36.0質量%以下、Bが0.92質量%以上1.15質量%以下、Tが残部(ここでTはFeまたはFeとCoであり、FeとCoの場合におけるCoはTのうち20質量%以下)である組成で表されるR−T−B系合金粉末Bと、
を準備する工程と、
前記R−T−B系合金粉末Aと前記R−T−B系合金粉末Bとを混合する工程と、
前記混合したR−T−B系合金粉末を所定形状の成形体に成形する工程と、
前記成形体を焼結する工程と、
を包含し、
前記R−T−B系合金粉末Bに含まれるRは、DyおよびTbの少なくとも1種からなる重希土類元素RHを4質量%以上、36質量%以下含み、前記R−T−B系合金粉末Bに含まれる重希土類元素RHの含有量は、前記R−T−B系合金粉末Aに含まれる重希土類元素RHの含有量より4質量%以上多く、
前記R−T−B系合金粉末Bの粒径D50は、前記R−T−B系合金粉末Aの粒径D50より1.0μm以上小さい、R−T−B系焼結磁石の製造方法。 - 前記混合工程において、R−T−B系合金粉末Aは粒径D50で3〜6μmである請求項1に記載のR−T−B系焼結磁石の製造方法。
- 前記混合工程において、R−T−B系合金粉末Bは粒径D50で1.5〜3μmである請求項1に記載のR−T−B系焼結磁石の製造方法。
- 前記R−T−B系合金粉末Aと前記R−T−B系合金粉末Bとを混合する工程では、R−T−B系合金粉末Aの質量:R−T−B系合金粉末Bの質量が60:40から90:10の範囲内に調整される請求項1から3のいずれかに記載のR−T−B系焼結磁石の製造方法。
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