KR20160077585A - Method for manufacturing amorphous powder core - Google Patents
Method for manufacturing amorphous powder core Download PDFInfo
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- KR20160077585A KR20160077585A KR1020140187654A KR20140187654A KR20160077585A KR 20160077585 A KR20160077585 A KR 20160077585A KR 1020140187654 A KR1020140187654 A KR 1020140187654A KR 20140187654 A KR20140187654 A KR 20140187654A KR 20160077585 A KR20160077585 A KR 20160077585A
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- 239000000843 powder Substances 0.000 title claims abstract description 229
- 238000000034 method Methods 0.000 title claims abstract description 30
- 238000004519 manufacturing process Methods 0.000 title abstract description 23
- 230000005291 magnetic effect Effects 0.000 claims abstract description 30
- 238000002156 mixing Methods 0.000 claims abstract description 25
- 239000011812 mixed powder Substances 0.000 claims abstract description 6
- 239000002245 particle Substances 0.000 claims description 49
- 229910045601 alloy Inorganic materials 0.000 claims description 12
- 239000000956 alloy Substances 0.000 claims description 12
- 229910000808 amorphous metal alloy Inorganic materials 0.000 claims description 9
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- 238000002360 preparation method Methods 0.000 claims description 9
- 230000005294 ferromagnetic effect Effects 0.000 claims description 8
- 230000001788 irregular Effects 0.000 claims description 5
- 238000001953 recrystallisation Methods 0.000 claims description 4
- 230000001747 exhibiting effect Effects 0.000 claims description 3
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- 238000000576 coating method Methods 0.000 description 9
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- 229910052802 copper Inorganic materials 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 239000010410 layer Substances 0.000 description 3
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- 229910002059 quaternary alloy Inorganic materials 0.000 description 3
- 238000005507 spraying Methods 0.000 description 3
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- 238000000137 annealing Methods 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
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- 230000000694 effects Effects 0.000 description 2
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- 229910052742 iron Inorganic materials 0.000 description 2
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- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910017061 Fe Co Inorganic materials 0.000 description 1
- 229910017082 Fe-Si Inorganic materials 0.000 description 1
- 229910017133 Fe—Si Inorganic materials 0.000 description 1
- 229910001030 Iron–nickel alloy Inorganic materials 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 238000000498 ball milling Methods 0.000 description 1
- 229910002056 binary alloy Inorganic materials 0.000 description 1
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- 229910052804 chromium Inorganic materials 0.000 description 1
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- 230000006835 compression Effects 0.000 description 1
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- 239000007769 metal material Substances 0.000 description 1
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- 239000012756 surface treatment agent Substances 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
Images
Classifications
-
- 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
-
- B22F1/0003—
-
- 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
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
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- Powder Metallurgy (AREA)
Abstract
A method for manufacturing an amorphous powder core is provided. According to the present invention, there is provided an amorphous powder producing method comprising the steps of: preparing an amorphous powder for producing an amorphous powder having soft magnetic properties; preparing a crystalline powder for producing a crystalline powder having a soft and hard phase; mixing a powder for mixing the amorphous powder and the crystalline powder; And a compression molding step of producing an amorphous powder core by compression-molding the mixed powder mixed in the powder mixing step into a desired core shape.
Description
The present invention relates to a method of manufacturing an amorphous powder core, and more particularly, to a method of manufacturing an amorphous powder core, which comprises mixing an amorphous alloy spherical powder having excellent soft magnetic characteristics and a crystalline soft magnetic powder having excellent softness, And to a method for manufacturing a powder core using the composite amorphous powder.
The amorphous powders have an advantage over the crystalline powders in terms of soft magnetic properties in the range of equivalent or similar chemical composition. Generally, it is advantageous to increase the filling rate because the powder flowability in the powder molding process step is good when the shape of the powder is spherical rather than irregular.
In addition, when the powder core is prepared by using a powder having a spherical powder size of not less than several tens of microns rather than a few microns of the powder, the soft magnetic characteristics of the powder core can be improved rather than using a finely small powder.
Therefore, when large particles of spherical amorphous alloy having good soft magnetic properties are used to produce powder cores, excellent soft magnetic properties and high packing ratio can be secured, which is expected to be a very useful advantage in manufacturing powder cores.
However, since the powder particles having an amorphous phase have softness at the compression molding step due to high physical properties such as high strength and high elasticity of 1.5Gpa or more inherent in amorphous phase, they are not good in formability than ordinary crystalline metal powder which is easy to be plasticized, Is a very difficult problem and has disadvantages.
In order to solve such a problem, copper was uniformly coated on an Fe-Si-B amorphous powder surface by electroless plating of Fe-Si-B amorphous powder in Korean Patent Laid-Open Publication No. 2007-0069948A, Si-B based amorphous powders formed on the Fe-Si-B-based amorphous powders are roughened by the surface of the powders, thereby increasing the bonding between the powders, thereby making it possible to form amorphous powders which can not be formed by plastic deformation.
In addition, among the crystalline powders, when the powder core is formed by powder particles which are very hard and weak in softness such as ferrite, or when the mechanical deficiency force in the cold state between the metal particles is weak, the cohesive force between the powder particles For the purpose of improvement, a method of adding a binder such as a small amount of organic material to secure molding strength, and then decomposing and removing it by burning during sintering may be used.
In order to overcome the difficulties of compression molding due to amorphous high elasticity and high strength properties at room temperature, it is necessary to preheat the molding mold to a temperature in the range of about 200 to 300 ° C to secure some deformation of the amorphous powder particles in a temperature range where the amorphous phase does not crystallize A high-pressure molding method may be applied.
Korean Patent Laid-Open Publication No. 2014-0071631A discloses a method of coating an amorphous powder with a phosphoric acid coating and a polyimide coating twice as an insulating material between the amorphous powders and using MoS 2 or graphite powder capable of lubrication of the powder at a high temperature, Discloses a method for producing amorphous core and nanocrystalline alloy pressure-sensitive core through automatic compression molding.
However, these methods may inevitably result in a reduction in the percent of magnetic body segregation due to the incorporation of some nonmagnetic material which may interfere with the soft magnetic properties, and excessive stress is accumulated in the powder particles due to high pressure molding, In order to ensure soft magnetic properties, stress relieving heat treatment after compression molding must be followed by post-processing. Nevertheless, sufficient molding strength obtained in compression molding of a general metal powder rich in ductility remains as a problem that is difficult to obtain.
Accordingly, the present invention relates to a method of forming an amorphous soft magnetic spherical powder core, which has a very small plastic deformation and a high strength, and has a spherical shape or a shape close to a sphere, The problem of poor moldability is solved.
The present invention is characterized in that amorphous spherical large particles having excellent soft magnetic properties are difficult to secure molding strength due to defects due to deformation between particles due to high physical properties of high strength and high elasticity inherent in amorphous phase during molding into powder cores, And to provide a method of manufacturing an amorphous powder core which is obtained by partially mixing and molding the metal powder particles having excellent and high ductility, thereby achieving a combination of high molding strength and excellent soft magnetic properties.
In general, the amorphous material has a very low plastic deformation amount and high mechanical properties. In the compression molding step of soft magnetic amorphous spherical powder cores, mechanical bonding force and cohesive force between powder particles are weak, The present invention provides a method for forming amorphous spherical powder and powdery crystalline powder having excellent soft magnetic properties at a predetermined ratio and mixing the insulating surface treatment agent in a minimum amount.
According to an embodiment of the present invention, there is provided a method for producing amorphous powder,
A crystalline powder preparation step of producing a crystalline powder having ductility and toughness,
A powder mixing step of mixing the amorphous powder and the crystalline powder, and
And a compression molding step of producing an amorphous powder core by compression molding the mixed powder mixed in the powder mixing step into a desired core shape.
The amorphous powder of the amorphous powder may be formed in any shape of square, flat, irregular, or spherical shapes.
The crystalline powder in the crystalline powder preparation step may have a plate-like particle shape.
An oxide film may be formed on the surface of the amorphous powder in the step of preparing the amorphous powder.
The stress relieving and recrystallization heat treatment may be performed so that the crystalline powder particles have sufficient ductility and electrical conductivity in the crystalline preparation step.
The oxide film may be formed to a thickness of 0.1 to 10 mu m.
When the amorphous powder has a spherical shape or a pseudo spherical shape, the size of the powder may be in the range of 10-150um.
The crystalline powder may be a ferromagnetic element exhibiting soft magnetic properties or an alloy powder composed of ferromagnetic elements.
The crystalline powder may be used in a state of higher flammability than the amorphous alloy powder.
When the amorphous powder and the crystalline powder are mixed in the powder mixing step, the mixing ratio may be in the range of 9.9: 0.1 to 0.1: 9.9 in weight ratio.
According to the embodiment of the present invention, an amorphous powder core manufacturing method in which an amorphous powder and a crystalline powder having a flame-retardant property and a soft magnetic characteristic are partially mixed, maintains the properties inherent to the amorphous alloy excellent in soft magnetic properties, There is an advantage that a high-strength amorphous powder core can be produced by compression-molding at room temperature without the need to preheat the powder and the mold freely.
Further, in order to insulate the powder particles, which are essential in the general metal powder core, an insulating coating material such as an organic material or an inorganic material may be mixed, or a post-process heat treatment may be performed to remove the stress accumulated in the particles after the powder is compression- There is an advantage to not have.
FIG. 1 is a schematic diagram of an amorphous powder core manufacturing method according to an embodiment of the present invention. FIG.
Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings, so that those skilled in the art can easily carry out the present invention. As will be readily understood by those skilled in the art, the following embodiments may be modified in various ways within the scope and spirit of the present invention. Wherever possible, the same or similar parts are denoted using the same reference numerals in the drawings.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. The singular forms as used herein include plural forms as long as the phrases do not expressly express the opposite meaning thereto. Means that a particular feature, region, integer, step, operation, element and / or component is specified, and that other specific features, regions, integers, steps, operations, elements, components, and / And the like.
All terms including technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the art to which the present invention belongs. Predefined terms are further interpreted as having a meaning consistent with the relevant technical literature and the present disclosure, and are not to be construed as ideal or very formal meanings unless defined otherwise.
To provide an amorphous powder core molding method capable of securing the excellent moldability of the soft magnetic amorphous powder core while owing to the inherent soft magnetic properties of the amorphous alloy proposed in the present invention and omitting the heat treatment step carried out in a subsequent step to be. It is necessary to generate and maintain a somewhat insulating film between the surfaces of the mutual particles with respect to the surface of the metal powder particle in contact with the surface.
In order to increase the mechanical bonding force between the powder particles by plastic deformation of the powder itself by the powder core compression molding, at least all or some of the particles constituting the powder core are abundant in the integrity and ductility of the powder itself, Interlocking with surrounding particles should be done. To solve the two technical problems of securing the molding strength by increasing the mechanical bonding force between the compression molded particles and the insulation between the powder particle surfaces by the plastic deformation.
First, the formation of the insulating layer on the surface of the particles is made by reinforcing the inherent insulating layer of the amorphous powder. Spherical amorphous powders are produced from molten metal by rapid solidification process. However, molten steel is dispersed into particles by gas atomization and at the same time it is contacted with coolant water to increase solid oxide film thickness on amorphous surface. So that the oxide film is not broken or removed.
Second, as a technical method for securing the compression-molding strength of the powder core by increasing the mechanical bonding force between particles by plastic deformation of the powder, the amorphous powder is mixed with the crystalline powder having a high ductility and high ductility, An amorphous crystalline mixed powder is used. In this case, some crystalline powder particles having good ductility at a low molding pressure are easily plastic-deformed to provide strong mechanical bonding with the powder particles, and the amorphous powder having high rigidity does not cause deformation and stress of the particles due to the molding pressure A solid insulating oxide film on the surface of the amorphous powder particles formed in the production of the powder is a method of maintaining the surface insulating function between the particles without being broken during the compression molding process.
FIG. 1 is a schematic diagram of an amorphous powder core manufacturing method according to an embodiment of the present invention. FIG.
Referring to FIG. 1, an amorphous powder core manufacturing method according to an embodiment of the present invention includes an amorphous powder manufacturing step (S10) for manufacturing an amorphous powder having soft magnetic properties,
(S20) for producing a crystalline powder having ductility and toughness,
A powder mixing step (S30) of mixing the amorphous powder and the crystalline powder, and
And a compression molding step (S40) of preparing an amorphous powder core by compression-molding the mixed powder mixed in the powder mixing step into a desired core shape.
Further, after the compression molding step (S40), a powder core post-treatment step (S50) such as an outer coating coating treatment of the powder core formed in the compression molding step (S40) may be included.
The shape of the amorphous powder in the amorphous powder production step (S10) may be any one of a square shape, a flake shape, an irregular shape, and a spherical shape.
When the amorphous powder has a spherical shape or a pseudo spherical shape, the size of the powder may be in the range of 10-150um.
In the amorphous powder production step (S10), amorphous powder is produced by gas spraying and quenching of cooling water, and an oxide film of a metal oxide layer may be formed on the surface of the amorphous powder, and the oxide film is formed to a thickness of 0.1 ~ .
The crystalline powder of the crystalline powder preparation step (S20) may have a plate-like particle shape.
In the crystalline preparation step (S20), the crystalline powder is prepared by a uniform powder production method such as gas spraying, water spraying, or ball milling. The crystalline powder is formed to have a plate-like particle shape, and the crystalline powder particles have sufficient ductility It is preferable that stress relief and recrystallization heat treatment be performed.
The crystalline powder may be a ferromagnetic element exhibiting soft magnetic characteristics or an alloy powder composed of ferromagnetic elements, and may be used in a state of higher flammability than the amorphous alloy powder.
In addition, the powder mixing step (S30) is a process of mixing the amorphous powder and the crystalline powder so that a relatively small amount of the crystalline powder is uniformly mixed and distributed.
When the amorphous powder and the crystalline powder are mixed in the powder mixing step, the mixing ratio may be in the range of 9.9: 0.1 to 0.1: 9.9 in weight ratio.
The compression molding step (S40) pressurizes the amorphous-crystalline mixed powder into a desired core shape to produce an amorphous powder core. In the powder core post-treatment step (S50), a post-treatment process such as the outer coating coating treatment of the formed core is performed.
Hereinafter, the process of the amorphous powder core manufacturing method according to one embodiment of the present invention will be described with reference to FIG.
In the step (S10) of producing the amorphous powder, the metal element constituted of the powder alloy composition is oxidized on the powder particle surface so that the oxide film is formed to a thickness of 0.1 to 10 탆. If the thickness of the oxide film is less than 0.1 탆, the insulating effect is insufficient. If the thickness of the oxide film is more than 10 탆, the oxide film is not rigid and the soft magnetic characteristics of the whole powder core may be deteriorated due to the increase of non- It is because. A more preferable thickness of the oxide film is preferably 2 to 5 mu m.
The alloy system of amorphous alloy powder is Fe-Si-B, Fe-Si-BC, Fe-Si-B-Nb-Cu, Fe-Si- -B It can be used in all of the ternary system, quaternary system, quaternary system, and quaternary system in Fe, Ni, and Co amorphous alloy systems, which have excellent magnetic properties and amorphous formation ability.
The amorphous powder may have any shape such as square, flat, irregular, or spherical. However, when spherical or pseudo spherical shape is used as the shape of the amorphous powder, the shape of the spherical or pseudo- 150 [mu] m, but it is preferably applied at a level of 30 ~ 70 [mu] m. When the amorphous powder size is less than 10 탆, the soft magnetic characteristic is disadvantageously decreased. When the amorphous powder size is more than 150 탆, the amorphous powder is filled with heat and moldability.
Further, the oxide film on the surface of the crystalline powder particles may or may not be present. When an oxide film is formed on the surface of crystalline powder particles, the thickness of the oxide film should not exceed 10 mu m for the same reason as described above.
Although the shape of the crystalline powder is not limited, the contact area with the amorphous powder particles and the shape ratio of the spherical powder and the square powder particles to the spherical powder and the square powder particles are easily changed between the powder particles in the compression molding step, Or the ratio of the width to the size of the flaky or needle-shaped or bar-shaped powder particles of about 1.1 to 5. When the squareness ratio is less than 1.1, the contact area increases and the effect of deformation is weak. When the squareness ratio is 5 or more, the crystalline powder particles mixed in the compression molding step interfere with the fluidity and decrease the filling property. Therefore, the squareness ratio of the crystalline powder is preferably about 1.5 to 3. The particle size of the crystalline powder is preferably adapted to correspond to a range of amorphous powder particle sizes to be mixed.
The alloy of the crystalline powder is a ferromagnetic binary alloy such as an Fe-Ni alloy, Fe-Al alloy, Fe-Si alloy or Fe-Co alloy having excellent soft magnetic properties, An alloy system in which elements such as Cr, Mn, Zr, V, Y, N, and Cu are added can be used, and single element ferromagnetic metal material powders such as Fe, Ni, and Co can also be applied.
In addition, it is preferable to apply the alloy powder particles in a state in which sufficient heat treatment for recrystallization annealing (annealing) is performed to minimize processing and residual stress generated in the crystalline powder manufacturing step.
When the amorphous powder and the crystalline powder are mixed before the powder core molding, the mixing ratio is in the range of 9.9: 0.1 to 0.1: 9.9 in weight ratio. It is preferable that the weight fraction of the amorphous powder is in the range of 90 to 50%. If the weight ratio of the amorphous powder is more than 99%, the formability is weak. If the weight fraction of the crystalline powder is more than 99%, the intrinsic characteristics of the amorphous powder are weak and the separate powder particle interlayer shall.
In the step of uniformly mixing the amorphous powder and the crystalline powder, the crystalline powder is plastic-deformed between the powder particles to generate a mechanical bonding force. So as not to be scattered to other particle ranges, to produce a metal powder core which retains the inherent characteristics of an amorphous powder excellent in soft magnetic properties.
The temperature of the molding die and the powder at the time of compression molding is set to be in the range of room temperature, and the temperature of the mold and the powder may be preheated to the range of 50 to 300 캜 which is higher than the room temperature. Thereafter, the heat treatment may be omitted in the molded powder core, and the heat treatment may be carried out at a temperature lower than the crystallization temperature of the amorphous powder, and the coating treatment of the powder core follows the established conditions and general methods.
In this way, by using a spherical powder having an amorphous phase excellent in soft magnetic properties in a material having an equivalent chemical composition and solving the problem of difficulty in manufacturing due to a weak compression-molding strength of the powder core, the formability of the powder core is good, A powder core having magnetic properties can be produced.
S10: Amorphous powder preparation step
S20: Crystalline powder preparation step
S30: Powder mixing step
S40: compression molding step
S50: powder core post-treatment step
Claims (10)
A crystalline powder preparation step of producing a crystalline powder having ductility and toughness,
A powder mixing step of mixing the amorphous powder and the crystalline powder, and
A powder compacting step of compressing the mixed powder to a desired core shape to produce an amorphous powder core;
≪ / RTI >
Wherein the amorphous powder in the step of preparing the amorphous powder is formed in a shape of a square, a flake, an irregular, or a spherical shape.
Wherein the crystalline powder of the crystalline powder has a plate-like particle shape.
Wherein an oxide film is formed on the surface of the amorphous powder in the step of preparing the amorphous powder.
Wherein stress relieving and recrystallization heat treatment are performed so that the crystalline powder particles have sufficient ductility and electrical conductivity in the crystalline preparation step.
Wherein the oxide film is formed to a thickness of 0.1 to 10 탆.
Wherein when the amorphous powder has a spherical or pseudo spherical shape, the size of the amorphous powder is in the range of 10 to 150 um.
Wherein the crystalline powder is a ferromagnetic element exhibiting soft magnetic properties or an alloy powder composed of ferromagnetic elements.
Wherein the crystalline powder is used in a state of higher flammability than the amorphous alloy powder.
Wherein the mixing ratio of the amorphous powder and the crystalline powder in the powder mixing step is in the range of 9.9: 0.1 to 0.1: 9.9 in weight ratio.
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| KR1020140187654A KR20160077585A (en) | 2014-12-23 | 2014-12-23 | Method for manufacturing amorphous powder core |
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| KR1020140187654A KR20160077585A (en) | 2014-12-23 | 2014-12-23 | Method for manufacturing amorphous powder core |
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