KR20180133459A - Iron metal glass alloy powder - Google Patents

Abstract

According to the present invention, it is possible to provide an iron-based metal element group mainly composed of Fe, a semimetal element group consisting of Si, B, P and C, and a small amount of at least one subcooling degree improving element selected from the group consisting of Nb and Mo Wherein the total amount of the group of the semi-metal elements and the total amount of the corrosion-resistant reforming components are within a predetermined range, and the iron-metal-glass alloy powder having a particle diameter of 30 탆 or less Powder.

Description

Iron metal glass alloy powder

The present invention relates to a flame-retardant iron-based metal glass alloy powder which can be used as a magnetic material for electronic parts such as inductors and choke coils.

Metal glass is one kind of amorphous metal, and up to now, alloy compositions of several hundred kinds such as iron and titanium have been found. Among them, the iron-based metal glass alloy is excellent in magnetic properties when it is subjected to powder compacting. Therefore, magnetic materials for producing electronic parts such as inductors and choke coils, electromagnetic shielding materials such as noise suppression sheets for electronic parts (Patent Document 1).

Since the noise suppressing sheet is generally used in the vicinity of an electronic device that generates heat, flame retardancy is required, and a noise suppressing sheet made of flame retardant by containing a large amount of flat soft magnetic material powder has been reported (Patent Document 2) . A noise suppression sheet made of a flame retardant by including the nanocrystalline soft magnetic metal powder and the acrylic binder resin has also been reported (Patent Document 3). However, the flame retardancy evaluated in these patent documents is the flame retardancy of the sheet and not the flame retardancy of the powder.

The ignition property is not a problem specific to the final product but a problem in the state of the material such as powder before forming the final product. This is because there is a risk that the material may ignite during manufacturing or handling after manufacture. Care should also be taken when transporting the material to the end product in a separate location or until the final product is formed.

A flame retardant magnetic shielding material having excellent flame retardancy and containing a predetermined amount of Al and / or Si, Cr and O and having a D ₅₀ of 10 to 40 μm and an aspect ratio (D ₅₀ / d) of 20 to 200 Flat iron alloy powder has been reported (Patent Document 4). A flattened iron ingot for flame retardant magnetic shielding comprising a predetermined amount of Al and / or Si, Cr, O and N and having a D ₅₀ of 10 to 40 μm and an aspect ratio (D ₅₀ / d) of 20 to 200 Alloy powders have also been reported (Patent Literature 5). These patent documents evaluate the flame retardancy of the powder, but the powder is not an amorphous powder.

Inductors, on the other hand, are used in mobile devices such as smart phones and electric vehicle systems such as power steering and airbags. 2. Description of the Related Art In recent years, high-frequency circuits have been developed for the purpose of high-speed operation processing of a CPU. As the frequency increases, a large current is required for the inductor. Normally, the inductor becomes large in accordance with the large current flow, but the inductor can be downsized by using a material having a high saturation magnetization. From such circumstances, the saturation magnetization, which is the magnetic property of the magnetic material constituting the inductor, becomes important.

As a material having a high saturation magnetization, there is a metal material containing Fe as a main material. Since metallic materials have high conductivity, they are not usable in a bulk state because they cause a large eddy current loss when used in a bulk type in a high frequency circuit. In general, the iron loss (generic term of energy loss due to the magnetic material in the inductor) of the soft magnetic material can be expressed by the following Modified Steinmetz equation.

Iron loss of soft magnetic material = hysteresis loss + eddy current loss

Since the eddy current loss depends on the grain size, it is effective to reduce the grain size in order to reduce the eddy current loss by reducing the eddy current loss.

On the other hand, it is known that the amorphous material exhibits excellent soft magnetic properties with low iron loss since it has no anisotropy derived from the crystal structure.

In order to miniaturize an inductor mounted on a mobile device or an electric system, it is required to have an iron metal glass alloy powder mainly composed of Fe and a small particle diameter.

Japanese Patent Application Laid-Open No. 2014-169482 Japanese Patent Application Laid-Open No. 2009-59753 Japanese Patent Application Laid-Open No. 2004-288941 Japanese Patent Laid-Open No. 10-4004 Japanese Patent Laid-Open No. 10-121103

Up to now, some iron metal glass alloy powders having an amorphous composition have been found, and the present applicants have also reported on Japanese Patent Application Laid-Open Nos. 2005-290468 and 2014-169482. However, it is not known that the iron-based metal glass alloy powder is easy to ignite.

Accordingly, it is an object of the present invention to solve the problem of easy ignition of iron-based metal-glass-alloy powder and to provide a flame-retardant iron-based metal-free glass alloy powder.

As a result of intensive studies, the present inventors have succeeded in making flame retardant by adjusting the composition of the iron-based metal glass alloy powder. That is, according to the present invention, there is provided the following iron-based metal-glass alloy powder:

[1] Iron metal glass alloy powder,

Wherein the iron-based metal-glass alloy has the following composition formula:

(Fe _1-st Co _s Ni _t ) _100-xy {(Si _a B _b ) _m (P _c C _d ) _n } _x M _y

And

Wherein the composition ratios of the iron metal element group Fe, Co and Ni are 19? X? 22, 0? Y? 6.0, 0? S? 0.35, 0? T? 0.35 and s +

The composition ratios of the semimetal element groups Si, B, P,

(0.5: 1)? (M: n)? (6: 1)

(2.5: 7.5)? (A: b)? (5.5: 4.5) and

(5.5: 4.5)? (C: d)? (9.5: 0.5)

Wherein the subcooling improving element group M is at least one member selected from the group consisting of Nb and Mo, and the iron-based metal-glass alloy further contains at least one member selected from the group consisting of Cr and Zr as a corrosion resistance modifying component , The content of the corrosion resistance modifying component is 2.8 to 5.5 wt% based on the total mass of the alloy component,

A particle diameter of 0.5 mu m or more,

The above iron-metal-glass-alloy powder.

[2] Iron metal glass alloy powder,

Wherein the iron-based metal-glass alloy has the following composition formula:

(Fe _{1 -s- t} Co _s Ni _t ) _{100-x- y} {(Si _a B _b ) _m (P _c C _d ) _n } _x M _y

Lt; / RTI >

Wherein the composition ratios of Fe, Co and Ni in the iron metal element group are 19? X? 26, 0? Y? 6.0, 0? S? 0.35, 0? T? 0.35 and s +

The composition ratios of the semimetal element groups Si, B, P,

(0.5: 1)? (M: n)? (6: 1)

(2.5: 7.5)? (A: b)? (5.5: 4.5) and

(5.5: 4.5)? (C: d)? (9.5: 0.5)

Wherein the subcooling improving element group M is at least one member selected from the group consisting of Nb and Mo, and the iron-based metal-glass alloy further contains at least one member selected from the group consisting of Cr and Zr as a corrosion resistance modifying component , The content of the corrosion resistance modifying component is 2.3 to 5.5 wt% based on the total mass of the alloy component,

A particle diameter of not less than 3 mu m,

The above iron-metal-glass-alloy powder.

[3] Iron metal glass alloy powder,

Wherein the iron-based metal-glass alloy has the following composition formula:

(Fe _1-st Co _s Ni _t ) _100-xy {(Si _a B _b ) _m (P _c C _d ) _n } _x M _y

Lt; / RTI >

Wherein the composition ratios of Fe, Co and Ni in the iron metal element group are 19? X? 26, 0? Y? 6.0, 0? S? 0.35, 0? T? 0.35 and s + t?

The composition ratios of the semimetal element groups Si, B, P,

(0.5: 1)? (M: n)? (6: 1)

(2.5: 7.5)? (A: b)? (5.5: 4.5) and

(5.5: 4.5)? (C: d)? (9.5: 0.5)

Wherein the subcooling improving element group M is at least one member selected from the group consisting of Nb and Mo and has a particle diameter of 10 to 30 占 퐉,

The above iron-metal-glass-alloy powder.

[4] Iron metal glass alloy powder,

Wherein the iron-based metal-glass alloy has the following composition formula:

(Fe _1-st Co _s Ni _t ) _100-xy {(Si _a B _b ) _m (P _c C _d ) _n } _x M _y

Lt; / RTI >

Wherein the composition ratios of the iron metal element group Fe, Co and Ni are 19? X? 22, 0? Y? 6.0, 0? S? 0.35, 0? T? 0.35 and s +

The composition ratios of the semimetal element groups Si, B, P,

(0.5: 1)? (M: n)? (6.1: 1),

(2.5: 7.5)? (A: b)? (5.6: 4.4) and

(4.2: 5.8)? (C: d)? (9.5: 0.5)

Wherein the subcooling improving element group M is at least one member selected from the group consisting of Nb and Mo, and the iron-based metal-glass alloy further contains at least one member selected from the group consisting of Cr and Zr as a corrosion resistance modifying component , The content of the corrosion resistance modifying component is 2.8 to 5.5 wt% based on the total mass of the alloy component,

A particle diameter of 0.5 mu m or more,

The above iron-metal-glass-alloy powder.

[5] Iron metal glass alloy powder,

Wherein the iron-based metal-glass alloy has the following composition formula:

(Fe _1-st Co _s Ni _t ) _100-xy {(Si _a B _b ) _m (P _c C _d ) _n } _x M _y

Lt; / RTI >

Wherein the composition ratios of Fe, Co and Ni in the iron metal element group are 19? X? 26, 0? Y? 6.0, 0? S? 0.35, 0? T? 0.35 and s +

The composition ratios of the semimetal element groups Si, B, P,

(0.5: 1)? (M: n)? (6.1: 1),

(2.5: 7.5)? (A: b)? (5.6: 4.4) and

(4.2: 5.8)? (C: d)? (9.5: 0.5)

Wherein the subcooling improving element group M is at least one member selected from the group consisting of Nb and Mo, and the iron-based metal-glass alloy further contains at least one member selected from the group consisting of Cr and Zr as a corrosion resistance modifying component , The content of the corrosion resistance modifying component is 2.3 to 5.5 wt% based on the total mass of the alloy component,

A particle diameter of not less than 3 mu m,

The above iron-metal-glass-alloy powder.

[6] Iron metal glass alloy powder,

Wherein the iron-based metal-glass alloy has the following composition formula:

(Fe _1-st Co _s Ni _t ) _100-xy {(Si _a B _b ) _m (P _c C _d ) _n } _x M _y

Lt; / RTI >

Wherein the composition ratios of Fe, Co and Ni in the iron metal element group are 19? X? 26, 0? Y? 6.0, 0? S? 0.35, 0? T? 0.35 and s +

The composition ratios of the semimetal element groups Si, B, P,

(0.5: 1)? (M: n)? (6.1: 1),

(2.5: 7.5)? (A: b)? (5.6: 4.4) and

(4.2: 5.8)? (C: d)? (9.5: 0.5)

Wherein the subcooling improving element group M is at least one member selected from the group consisting of Nb and Mo and has a particle diameter of 10 to 30 占 퐉,

The above iron-metal-glass-alloy powder.

[7] The iron-based metal-based glass alloy according to any one of the items [1] to [4], wherein the iron-based metal-free glass alloy contains at least one member selected from the group consisting of Cr and Zr as a corrosion resistant reforming component in an amount exceeding 0 wt% By weight based on the total weight of the iron-based metal-free glass alloy powder.

[8] Iron metal glass alloy powder according to [1], [2], [4], [5] or [7], wherein the corrosion resistance reforming component is Cr.

[9] A molded article produced by using the iron-based metal glass alloy powder according to any one of [1] to [8].

According to the present invention, a flame-retardant iron-based metal glass alloy powder can be provided. By eliminating the risk of igniting the material during manufacturing or handling after manufacture, it is possible to simplify the storage and transporting method until the final product is formed, and thus it is possible to use a safe and low-cost material.

In addition, the iron-based metal glass alloy powder of the present invention maintains high magnetic properties. Therefore, it can be suitably used as a material for powder molding of various electronic parts and as a material for a paint for forming a magnetic film on an electronic circuit substrate.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional view showing the concept of a water atomization apparatus used in the production of the iron-based metal glass alloy powder of the present invention. FIG.

In the present specification, the elements constituting the " iron metal element group " are Fe, Co, and Ni.

In the present specification, the elements constituting the "semi-metallic element group" are Si, B, P, and C.

In the present specification, the elements constituting the " supercooling improving element group " are Nb and Mo.

In the present specification, the " content ratio " of the constituent elements of the alloy is a ratio of the content of the constituent elements (wt (wt%)) based on the total mass of the iron- %). The composition ratio in the above composition formula indicates atomic% (atomic%) or atomic ratio unless otherwise specified.

As used herein, the term "particle diameter" refers to an average particle diameter (median diameter, D ₅₀ ) unless otherwise specified.

By adjusting each composition ratio in the above composition formula (basic composition), it is possible to obtain an iron-based metal glass alloy which is flame retardant even when the particle diameter is smaller than that of the conventional product. The present invention includes first to third embodiments classified by composition ratio and particle diameter. Further, in this specification, unless otherwise stated, " present invention " refers to the whole form.

The first embodiment is characterized in that 19? X? 22, the corrosion-resistant reforming component is 2.8 to 5.5 wt% based on the total mass of the alloy component, and the particle diameter is 0.5 m or more and less than 3 m Alloy powder.

The second mode is characterized in that 19? X? 26, the corrosion-resistant reforming component is 2.3 to 5.5 wt% based on the total mass of the alloy component, and the particle diameter is 3 m or more and less than 10 m Alloy powder.

The third embodiment is characterized in that 19? X? 26, the corrosion-resistant reforming component is 0 to 5.5% by weight based on the total mass of the alloy component, and the particle diameter is 10 to 30 占 퐉. .

First, the matters common to all the forms will be described.

1. Composition ratio of total form

1-1. (S, t, s + t) of the iron metal element group,

In the above basic composition, the composition ratios of the iron metal element group are 0? S? 0.35, 0? T? 0.35, and s + t?

s and t may be zero. That is, it is not necessary to include Co or Ni, which is an iron metal element other than Fe. Co and Ni are expensive, but even if they are not included, iron metal glass alloy powder can be obtained at lower cost because it has excellent magnetic properties and corrosion resistance and can obtain supercooling of 40 K or more.

When s + t > 0.35, the content of Co and Ni is increased and the material cost is increased, and the degree of supercooling is so small that it can not be measured actually. As a result, subcooling of 40 K or more, which is a condition for forming the amorphous composition, can not be obtained.

1-2. The composition ratios (a, b, m, c, d, n)

The range of the composition ratios (a, b, m, c, d, n) of the respective elements constituting the semimetal element group is within the range of the composition ratio (x)

(0.5: 1)? (M: n)? (6.1: 1),

(2.5: 7.5)? (A: b)? (5.6: 4.4) and

(4.2: 5.8)? (C: d)? (9.5: 0.5)

. Preferably,

(0.5: 1)? (M: n)? (6: 1)

(2.5: 7.5)? (A: b)? (5.5: 4.5) and

(5.5: 4.5)? (C: d)? (9.5: 0.5)

.

When the composition ratio of the semimetal element group is out of the above range, it is difficult to obtain the supercooling degree of? Tx? 40K.

The composition ratio of the semi-

(1.5: 1)? (M: n)? (5.5: 1)

(3.5: 6.5)? (A: b)? (6.5: 3.5) and

(6.0: 4.0)? (C: d)? (8.5: 1.5).

More preferably,

(2.5: 1)? (M: n)? (3.5: 1)

(4.3: 5.7)? (A: b)? (5.2: 4.8) and

(6.5: 3.5)? (C: d)? (7.0: 3.0).

By setting the ratio of the semimetal element group to such a range, the magnetic property and corrosion resistance of the iron-based metal-glass alloy powder can be further improved.

1-3. The composition ratio (y) of the subcooling improving element group

The composition ratio of the subcooling improving element group is 0? Y? 6.0, preferably 0.05? Y? 2.4, more preferably 0.15? Y? By setting the composition ratio of the subcooling improving element group to such a range, the magnetic properties can be improved. However, since Nb or Mo is an expensive rare metal, it is preferable that the composition ratio of Nb or Mo is as low as possible within a range where necessary magnetic characteristics can be obtained. If the composition ratio of the subcooling improving element group is excessive, the effect of improving the supercooling degree reaches the saturation value and the magnetic property tends to be relatively lowered.

The reason why the composition ratios of either Nb or Mo and the composition ratios of both are the same is that the atomic radius and atomic weight are approximate with the chemical elements being similar to each other.

2. Composition ratio and grain size

2-1. First type

2-1-1. The composition ratio (x) of the semi-

The composition ratio (x) of the total of the semimetal element groups in the first embodiment is 19? X? 22.

From the viewpoint of flame retardance, supercooling and magnetic properties, a range of 21? X? 22 is preferable.

Further, the lower limit of x is set from the viewpoint of obtaining an undercooling degree of? Tx? 40K and obtaining an amorphous single phase. The upper limit of x is set in consideration of the first of all from the viewpoint of the flame retardancy and secondly in consideration of the prevention of deterioration of the magnetic property accompanying the decrease of the Fe amount and suppression of the material cost.

2-1-2. Corrosion resistance modifying component

The content of the corrosion-resistant reforming component in the first embodiment is 2.8 to 5.5 wt%, preferably 2.8 to 4.0 wt%, based on the total mass of the alloy component. Cr and Zr contained in the iron-based metal glass alloy powder form an oxide film on the surface of the iron-based metal-based glass alloy powder, so that the corrosion resistance is improved. As the corrosion resistance reforming component, Cr is preferable for economical reasons.

The iron-based metal-free glass alloy powder of the first embodiment of the present invention may further contain Al as a corrosion-resistant reforming component. Al has an effect of increasing the hardness of the oxide film formed by Cr and / or Zr, although an oxide film is formed on the surface of the iron-based metal-glass alloy powder. When the hardness of the oxide film is increased, the corrosion resistance is further improved. Further, when the iron-based metal glass alloy powder is produced by the atomization method to be described later, Al contributes to spheroidization of the powder.

The content of Al is 0.01 to 0.75 wt% and the content of the corrosion-resistant reforming component containing Al is 1.0 to 0.75 wt% based on the total mass of the iron-based metal-free glass alloy powder of the first embodiment of the present invention, It is preferably 5.0 wt%. Further, it is preferable that the content of Al is 0.03 to 0.50 wt%, and the content of the corrosion-resistant reforming component containing Al is 1.5 to 1.9 wt%. When the latter composition is used, not only the corrosion resistance but also the magnetic properties are further improved.

The iron-based metal glass alloy powder of the first embodiment of the present invention may further include at least one kind selected from the group consisting of V, Ti, Ta, Cu and Mn as the corrosion resistance-improving subcomponent. Thus, excellent magnetic properties can be obtained while reducing the content of the corrosion-resistant reforming component. The total content of the corrosion resistant reforming subcomponent is preferably 0.03 to 0.70 wt%, more preferably 0.05 to 0.50 wt%, and 0.10 to 0.30 wt%, based on the total mass of the iron metal glass free alloy powder of the first embodiment of the present invention desirable. Like the case of Al, the corrosion resistance improving subcomponent can also improve the corrosion resistance by forming an oxide film on the surface of the iron-based metal glass alloy powder. In addition, the resistivity of the iron-based metal-glass alloy powder can be improved by the synergistic effect with the corrosion-resistant reforming component.

2-1-3. Particle diameter

The iron metal glass alloy powder of the first embodiment of the present invention has a particle diameter of 0.5 占 퐉 or more and less than 3 占 퐉. Generally, a smaller particle diameter is advantageous in that the eddy current loss in iron loss is lowered and excellent magnetic properties are obtained, but the disadvantage is that the reactivity is increased because the specific surface area is increased and the reliability of the material is lowered. However, if the iron-based metal glass alloy powder of the composition of the first aspect of the present invention is used, such drawbacks can be eliminated. In general, when the particle diameter is small, the iron-based metal-free glass alloy powder tends to be corroded. However, the iron-based metal-free glass alloy powder of the first embodiment of the present invention has a particle diameter of 0.5 탆 or more, Good.

2-2. The second type

2-2-1. The composition ratio (x) of the semi-

The composition ratio (x) of the total sum of the group of the semimetal element in the second embodiment is 19? X? 26. From the viewpoints of flame retardancy, supercooling and magnetic properties, a range of 21? X? 26 is preferable.

Further, the lower limit of x is set from the viewpoint of obtaining an undercooling degree of? Tx? 40K and obtaining an amorphous single phase. The upper limit of x is set first in view of flame retardancy and secondly in consideration of suppression of magnetic property deterioration accompanied by decrease in Fe amount and suppression of material cost.

2-2-2. Corrosion resistance modifying component

The content of the corrosion-resistant reforming component in the second embodiment is 2.3 to 5.5 wt%, preferably 2.3 to 4.0 wt%, based on the total mass of the alloy component. Cr and Zr contained in the iron-based metal glass alloy powder form an oxide film on the surface of the iron-based metal-based glass alloy powder, so that the corrosion resistance is improved. As the corrosion resistance reforming component, Cr is preferable for economical reasons.

The description of the corrosion resistance reforming component (Al) and the corrosion resistance improving subcomponent (at least one member selected from the group consisting of V, Ti, Ta, Cu and Mn) in a single layer is based on the description of the first embodiment.

2-2-3. Particle diameter

The particle size of the iron-based metal-free glass alloy powder of the second embodiment of the present invention is 3 탆 or more and less than 10 탆. Generally, a smaller particle diameter is advantageous in that the eddy current loss in iron loss is lowered and excellent magnetic properties are obtained, but the disadvantage is that the reactivity is increased because the specific surface area is increased and the reliability of the material is lowered. However, if the iron-based metal glass alloy powder of the composition of the second aspect of the present invention is used, such drawbacks can be eliminated. In general, when the particle diameter is small, the iron-based metal-free glass alloy powder tends to be corroded. However, the iron-based metal-free-glass alloy powder of the second embodiment of the present invention has a particle diameter of 3 탆 or more, Good.

2-3. Third form

2-3-1. The composition ratio (x) of the semi-

The composition ratio (x) of the total of the semimetallic element groups in the third embodiment is 19? X? 26. From the viewpoints of flame retardancy, supercooling and magnetic properties, a range of 21? X? 26 is preferable.

Further, the lower limit of x was set in view of obtaining an undercooling degree of? Tx? 40K and obtaining an amorphous single phase. The upper limit of x is set in consideration of the first of all from the viewpoint of the flame retardancy and secondly in consideration of the prevention of deterioration of the magnetic property accompanying the decrease of the Fe amount and suppression of the material cost.

2-3-2. Corrosion resistance modifying component

The content of the corrosion-resistant reforming component in the third embodiment is 0 to 5.5 wt%, preferably 3.0 to 4.0 wt%, based on the total mass of the alloy component. Cr and Zr contained in the iron-based metal glass alloy powder form an oxide film on the surface of the iron-based metal-based glass alloy powder, so that the corrosion resistance is improved. As the corrosion resistance reforming component, Cr is preferable for economical reasons.

The description of the corrosion resistance reforming component (Al) and the corrosion resistance improving subcomponent (at least one member selected from the group consisting of V, Ti, Ta, Cu and Mn) in a single layer is based on the description of the first embodiment.

2-3-3. Particle diameter

The particle size of the iron-based metal-free glass alloy powder of the third embodiment of the present invention is 10 to 30 占 퐉. Generally, a smaller particle diameter is advantageous in that the eddy current loss in iron loss is lowered and excellent magnetic properties are obtained, but the disadvantage is that the reactivity is increased because the specific surface area is increased and the reliability of the material is lowered. However, if the iron-based metal glass alloy powder of the composition of the third aspect of the present invention is used, such drawbacks can be eliminated. Generally, when the particle diameter is small, the iron-based metal glass alloy powder is easily corroded. However, the iron-based metal-free glass alloy powder of the third embodiment of the present invention has good corrosion resistance even if the particle diameter is as small as 10 to 30 μm.

3. Manufacturing Method

The iron-based metal glass alloy powder of the present invention can be produced by the water atomization method. The water atomization method is a method in which iron metal glass alloy powder can be manufactured in the air, and the manufacturing cost can be reduced by lowering the equipment cost and the manufacturing cost.

The atomization apparatus of the water atomization method is composed of a melting furnace 1 in which a bottom plate formed by drilling a molten metal orifice 5 downward is integrally formed on a side plate provided upright in a cylindrical shape as shown in Fig. An induction heating coil 2 spirally arranged on the entire outer peripheral surface of the side plate of the melting crucible 1, a molten metal stopper 3 loaded in the melting crucible 1 for opening and closing the melting crucible 1, And an atomization nozzle 6 disposed below the molten metal orifice 5.

A molten raw material 4 (base composition, corrosion resistance modifying component, and corrosion resistance modifying subcomponent, if necessary) corresponding to the iron-based metal glass alloy powder of the present invention is placed in the melting crucible 1, Of the total weight of the product. Then, the molten raw material 4 is heated to a temperature not lower than the melting point by the induction heating coil 2 to melt it. Then the molten metal orifice 5 is opened with the molten metal stopper 3 and the molten metal 4 is dropped from the molten metal orifice 5. The atomization nozzle (6) injects water to form a water film below the molten metal orifice (5). The molten metal dropped from the molten metal orifice 5 collides with the corresponding water film, is crushed, rapidly cooled, and solidifies. The molten metal solidified and dropped into the water 8 in a water tank (not shown) disposed below the atomization nozzle is further cooled. The powder is recovered and subjected to a drying step and a classification step to obtain an iron-based metal glass alloy powder having a desired composition and particle size.

The iron-based metal glass alloy powder of the present invention does not crystallize even when the iron-based metal-glass-alloyed powder is produced at a slower cooling rate than the conventional iron-based metal-based glass alloy. That is, it is possible to easily produce an amorphous single-phase iron-based metal glass alloy powder containing no crystal phase even in a general-purpose mass production facility with a slow cooling rate. This is because the supercooling degree DELTA Tx expressed by the difference between the crystallization starting temperature Tx and the glass transition temperature Tg is large and the amorphous forming ability is improved.

Since the iron-based metal glass alloy powder obtained through the above steps has a high degree of sphericity, for example, iron metal glass alloy powder is filled in a molding die to form a magnetic core, It is possible to increase the packing density of the iron-based metal-glass-alloy powder, and thus it is possible to produce products such as electronic parts having excellent magnetic properties.

In the present invention, the particle diameter of the iron-based metal-free glass alloy powder may be controlled by changing the production conditions of the water atomization method, or may be classified using a sieve or the like to obtain a powder having a desired particle diameter.

Example

The basic composition and the corrosion resistance reforming component were adjusted so that the corrosion resistance modifying component had the content shown in the following table and the obtained material mixture was melted in the high frequency induction furnace and the powder having the desired composition was obtained by the water atomization method under the following conditions .

≪ Water atomization condition >

· Water pressure: 100MPa

· Quantity: 100L / min

· Water temperature: 20 ℃

· Orifice diameter: φ4 mm

· Molten metal raw material temperature: 1,500 ℃

The resulting iron-based metal glass alloy powder was classified into D ₅₀ = 2 ± 0.3 μm using an air flow classifier (Nisshin Engineering: Turbo Crushfire). The particle diameter was measured by a laser diffraction particle size distribution analyzer (Nikkiso Sole: Microtrac MT3300EX II (wet)). The content of the semimetal element and the subcooling improving element was measured by an ICP emission spectrometer (Hitachi High-Tech Science Co., Ltd.: SPS3500DD).

≪ Evaluation of flame retardancy &

The obtained iron metal glass alloy powder of each of the first to third forms was examined for ignitability by the small-gas flame ignition test of the dangerous goods class II test method specified in the fire fighting method. Specifically, the evaluation powder is expanded to a hemispherical shape having a width of 30 mm and a height of 15 mm. Using a simple ignition mechanism (portable simple gas lighter) with a flame length of 70 mm, the flame is brought into contact with the sample for 10 seconds at a contact angle of 30 degrees. If combustion does not continue, this operation is repeated 10 times. If the ignition is ignited within 3 seconds of the sample which has ignited once even after the flame has been removed and the flame combustion or the unleaded combustion has continued, the ignition is easily ignited within 10 seconds after exceeding 3 seconds (first type combustible solid) (Second type combustible solid). However, in this evaluation, it was judged to be ignitable because it would be dangerous if ignited within 10 seconds. It was judged that there was no ignition in the case where ignition exceeded 10 seconds or combustion was not continued. The presence or absence of ignition was evaluated based on the following evaluation category. The results are listed in the following table.

<Evaluation division>

○:

×: ignition

Table 4 shows the composition of the iron-based metal glass alloy powder of the second embodiment, and the particle diameter is 3 占 퐉 or more and less than 10 占 퐉. Since these powders can be expected from the results of Tables 1 to 3 that the particles have a small particle diameter and that even if the particle size is large even if the particles are unfired, the flame resistance test is not carried out.

The symbol &quot; * &quot; placed on the right side of the number in the column of &quot; YES &quot; The symbol &quot; * &quot; placed on the upper right of the digits in the y column indicates that M is Mo.

The iron-based metal glass alloy powder of the present invention can be suitably used as a magnetic material for producing electronic components such as inductors and choke coils, and also as a material for electromagnetic shields, noise suppression sheets, noise suppression filters and the like. The iron-based metal glass alloy powder of the present invention can also be used as a projecting material or an abrasive.

1: melting crucible
2: induction heating coil
3: molten metal stopper
4: molten raw material
5: Orifice
6: atomization nozzle
7:
8: water

Claims (9)

Iron metal glass alloy powder,
Wherein the iron-based metal-glass alloy has the following composition formula:
(Fe _1-st Co _s Ni _t ) _100-xy {(Si _a B _b ) _m (P _c C _d ) _n } _x M _y
Lt; / RTI &gt;
Wherein the composition ratios of the iron metal element group Fe, Co and Ni are 19? X? 22, 0? Y? 6.0, 0? S? 0.35, 0? T? 0.35 and s +
The composition ratios of the semimetal element groups Si, B, P,
(0.5: 1)? (M: n)? (6: 1)
(2.5: 7.5)? (A: b)? (5.5: 4.5) and
(5.5: 4.5)? (C: d)? (9.5: 0.5)
Wherein the subcooling improving element group M is at least one member selected from the group consisting of Nb and Mo, and the iron-based metal-glass alloy further contains at least one member selected from the group consisting of Cr and Zr as a corrosion resistance modifying component , The content of the corrosion resistance modifying component is 2.8 to 5.5 wt% based on the total mass of the alloy component,
A particle diameter of 0.5 mu m or more,
The above iron-metal-glass-alloy powder. Iron metal glass alloy powder,
Wherein the iron-based metal-glass alloy has the following composition formula:
(Fe _1-st Co _s Ni _t ) _100-xy {(Si _a B _b ) _m (P _c C _d ) _n } _x M _y
Lt; / RTI &gt;
Wherein the composition ratios of Fe, Co and Ni in the iron metal element group are 19? X? 26, 0? Y? 6.0, 0? S? 0.35, 0? T? 0.35 and s +
The composition ratios of the semimetal element groups Si, B, P,
(0.5: 1)? (M: n)? (6: 1)
(2.5: 7.5)? (A: b)? (5.5: 4.5) and
(5.5: 4.5)? (C: d)? (9.5: 0.5)
Wherein the subcooling improving element group M is at least one member selected from the group consisting of Nb and Mo, and the iron-based metal-glass alloy further contains at least one member selected from the group consisting of Cr and Zr as a corrosion resistance modifying component , The content of the corrosion resistance modifying component is 2.3 to 5.5 wt% based on the total mass of the alloy component,
A particle diameter of not less than 3 mu m,
The above iron-metal-glass-alloy powder. Iron metal glass alloy powder,
Wherein the iron-based metal-glass alloy has the following composition formula:
(Fe _1-st Co _s Ni _t ) _100-xy {(Si _a B _b ) _m (P _c C _d ) _n } _x M _y
Lt; / RTI &gt;
Wherein the composition ratios of Fe, Co and Ni in the iron metal element group are 19? X? 26, 0? Y? 6.0, 0? S? 0.35, 0? T? 0.35 and s +
The composition ratios of the semimetal element groups Si, B, P,
(0.5: 1)? (M: n)? (6: 1)
(2.5: 7.5)? (A: b)? (5.5: 4.5) and
(5.5: 4.5)? (C: d)? (9.5: 0.5)
Wherein the subcooling improving element group M is at least one member selected from the group consisting of Nb and Mo and has a particle diameter of 10 to 30 占 퐉,
The above iron-metal-glass-alloy powder. Iron metal glass alloy powder,
Wherein the iron-based metal-glass alloy has the following composition formula:
(Fe _1-st Co _s Ni _t ) _100-xy {(Si _a B _b ) _m (P _c C _d ) _n } _x M _y
Lt; / RTI &gt;
Wherein the composition ratios of the iron metal element group Fe, Co and Ni are 19? X? 22, 0? Y? 6.0, 0? S? 0.35, 0? T? 0.35 and s +
The composition ratios of the semimetal element groups Si, B, P,
(0.5: 1)? (M: n)? (6.1: 1),
(2.5: 7.5)? (A: b)? (5.6: 4.4) and
(4.2: 5.8)? (C: d)? (9.5: 0.5)
Wherein the subcooling improving element group M is at least one member selected from the group consisting of Nb and Mo, and the iron-based metal-glass alloy further contains at least one member selected from the group consisting of Cr and Zr as a corrosion resistance modifying component , The content of the corrosion resistance modifying component is 2.8 to 5.5 wt% based on the total mass of the alloy component,
A particle diameter of 0.5 mu m or more,
The above iron-metal-glass-alloy powder. Iron metal glass alloy powder,
Wherein the iron-based metal-glass alloy has the following composition formula:
(Fe _1-st Co _s Ni _t ) _100-xy {(Si _a B _b ) _m (P _c C _d ) _n } _x M _y
Lt; / RTI &gt;
Wherein the composition ratios of Fe, Co and Ni in the iron metal element group are 19? X? 26, 0? Y? 6.0, 0? S? 0.35, 0? T? 0.35 and s +
The composition ratios of the semimetal element groups Si, B, P,
(0.5: 1)? (M: n)? (6.1: 1),
(2.5: 7.5)? (A: b)? (5.6: 4.4) and
(4.2: 5.8)? (C: d)? (9.5: 0.5)
Wherein the subcooling improving element group M is at least one member selected from the group consisting of Nb and Mo, and the iron-based metal-glass alloy further contains at least one member selected from the group consisting of Cr and Zr as a corrosion resistance modifying component , The content of the corrosion resistance modifying component is 2.3 to 5.5 wt% based on the total mass of the alloy component,
A particle diameter of not less than 3 mu m,
The above iron-metal-glass-alloy powder. Iron metal glass alloy powder,
Wherein the iron-based metal-glass alloy has the following composition formula:
(Fe _1-st Co _s Ni _t ) _100-xy {(Si _a B _b ) _m (P _c C _d ) _n } _x M _y
Lt; / RTI &gt;
Wherein the composition ratios of Fe, Co and Ni in the iron metal element group are 19? X? 26, 0? Y? 6.0, 0? S? 0.35, 0? T? 0.35 and s +
The composition ratios of the semimetal element groups Si, B, P,
(0.5: 1)? (M: n)? (6.1: 1),
(2.5: 7.5)? (A: b)? (5.6: 4.4) and
(4.2: 5.8)? (C: d)? (9.5: 0.5)
Wherein the subcooling improving element group M is at least one member selected from the group consisting of Nb and Mo and has a particle diameter of 10 to 30 占 퐉,
The above iron-metal-glass-alloy powder. 7. The iron-based alloy according to claim 3 or 6, wherein the iron-based metal-free glass alloy comprises at least one member selected from the group consisting of Cr and Zr as a corrosion-resistant reforming component in an amount exceeding 0 wt% By weight, and further containing at most 5.5% by weight of the iron-based metal glass alloy powder. The iron-metal-glass-alloy powder according to any one of claims 1, 2, 4, 5, and 7, wherein the corrosion-resistant reforming component is Cr. A molded article produced by using the iron-based metal glass alloy powder according to any one of claims 1 to 8.

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