US20030211000A1 - Method for producing improved an anisotropic magent through extrusion - Google Patents

Method for producing improved an anisotropic magent through extrusion Download PDF

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Publication number
US20030211000A1
US20030211000A1 US10/275,221 US27522102A US2003211000A1 US 20030211000 A1 US20030211000 A1 US 20030211000A1 US 27522102 A US27522102 A US 27522102A US 2003211000 A1 US2003211000 A1 US 2003211000A1
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US
United States
Prior art keywords
container
particle charge
extrusion
magnet
thermal treatment
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/275,221
Inventor
Vijay Chandhok
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Advanced Materials Corp
Original Assignee
Advanced Materials Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Advanced Materials Corp filed Critical Advanced Materials Corp
Priority to US10/275,221 priority Critical patent/US20030211000A1/en
Priority claimed from PCT/US2001/007560 external-priority patent/WO2001083128A1/en
Assigned to ADVANCED MATERIALS CORPORATION reassignment ADVANCED MATERIALS CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHANDHOK, VIJAY K.
Assigned to ADVANCED MATERIALS CORPORATION reassignment ADVANCED MATERIALS CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHANDOK, VIJAY K.
Publication of US20030211000A1 publication Critical patent/US20030211000A1/en
Assigned to ENERGY, UNITED STATES DEPARTMENT OF reassignment ENERGY, UNITED STATES DEPARTMENT OF CONFIRMATORY LICENSE (SEE DOCUMENT FOR DETAILS). Assignors: ADVANCED MATERIALS CORPORATION
Abandoned legal-status Critical Current

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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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/20—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by extruding
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12—Both compacting and sintering
    • B22F3/1208—Containers or coating used therefor
    • B22F3/1216—Container composition
    • B22F3/1241—Container composition layered
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0253—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing permanent magnets
    • H01F41/0273—Imparting anisotropy
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F2003/1042—Sintering only with support for articles to be sintered
    • B22F2003/1046—Sintering only with support for articles to be sintered with separating means for articles to be sintered

Definitions

  • This invention relates to a method for producing, by an extrusion process, an improved anisotropic magnet which is crack-free and has enhanced magnetic properties.
  • the coefficient of thermal expansion between the container and the magnet charge are at variance such that the aforementioned tensile stresses are created. During cooling, these stresses result in cracking of the finished product which, in turn, has prevented the use of this process to be used commercially. Further, magnets produced through the extrusion processes of the prior art have lacked enhanced magnetic properties of similar magnets produced by other means.
  • An additional object of this invention is to provide an improved method for producing anisotropic magnet bodies wherein the internal surface of the container involved in the extrusion process is lined with a material to prevent the bonding of the container to the magnet charge and reduce resultant tensile stresses which are created during cooling.
  • inert materials such as fused silica, high temperature refractory cement and boron nitride. These materials may be applied as a paste or spray.
  • boron nitride provides a smooth surface on the final magnetic body.
  • Other possible coating materials include zirconia, yttria, ceria and other rare earth oxides and their combinations.
  • the improved extrusion process described by this invention has direct application to the production of NdFeB anisotropic magnets. Additionally, the improved extrusion process described by this invention may be used to fabricate hexagonal ferrite magnets (i.e., barium, strontium and lanthanum ferrites) and provide high energy products in the range 2-5 MG Oe and, also, samarium—iron nitrides of the composition Sm 2 Fe 17 N x and MnBi magnets.
  • hexagonal ferrite magnets i.e., barium, strontium and lanthanum ferrites
  • the post-extrusion thermal treatment consists of holding the extrusion product at temperatures from 1000° F. to 1750° F. for 1 to 10 hours.
  • the container involved in the extrusion process can be coated with a material to prevent the bonding of the interior surface of the container to the charge and resulting magnetic body.
  • the coating is comprised of an inert material from the group consisting of fused silica, high temperature refractory cement and boron nitride. These materials may be applied as a paste or spray.
  • boron nitride is used as the coating because it produces a final magnetic body which has a smoother surface.
  • the coating of the internal surface of the container involved in the extrusion process can also be comprised of the group consisting of zirconia, yttria, ceria and other rare earth oxides and their combinations.
  • This improved extrusion process has, in a preferred embodiment, application to Nd(Fe,Co) (B,Ga) magnets.
  • this improved extrusion process is also applicable to fabrication of hexagonal ferrites (i.e., barium, strontium and lanthanum ferrites) and, in particular, hexagonal ferrites that produce high energy products in the range of 2-5 MG Oe and Sm 2 Fe 17 N x and MnBi magnets.
  • the magnetic properties of an extruded anisotropic magnet can be improved or enhanced through a post-extrusion thermal treatment.
  • the extrusion product i.e. the resulting magnetic body
  • a post-extrusion thermal treatment which consists of holding the extrusion product at temperatures from between 1000° F. to 1750° F. for several hours. Through this post-extrusion treatment, enhanced magnetic properties such as remanence, coercivity and energy product are achieved.

Abstract

A method for producing an improved anisotropic magnet through an extrusion process wherein the container involved in the extrusion process is first coated, on its internal surface, with a material to prevent the bonding of the interior surface to the particle charge to be extruded and, thereby, to prevent cracking due to tensile stresses. In addition, an improved anisotropic extrusion product, with enhanced magnetic properties, can be obtained by holding the temperature of the extrusion product at temperatures between 1000° F. and 1750° F. for between 1 and 10 hours.

Description

    STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
  • [0001] This invention was made with government support under a small business research and development grant for “A Simple Process to Manufacture Grain Aligned Permanent Magnets” awarded by the U.S. Department of Energy (Grant No. DE-FG02-97-ER82313). The Government has certain rights to this invention.
    • FIELD OF THE INVENTION
  • This invention relates to a method for producing, by an extrusion process, an improved anisotropic magnet which is crack-free and has enhanced magnetic properties. [0002]
    • BACKGROUND OF THE INVENTION
  • It is known to produce a fully dense permanent magnet alloy particle having crystal alignment through an extrusion process whereby a particle charge of a permanent magnet alloy composition is placed in a container and the container is evacuated, sealed and heated to an elevated temperature. The container is then extruded to achieve crystal alignment and to compact the charge to full density to produce the desired fully dense body. U.S. Pat. No. 4,881,984 (Chandhok et al.) describes such a method. [0003]
  • In practice however, this method has suffered from disadvantages which have precluded use of the resulting magnet bodies. More specifically, the extruded magnet body has been prone to cracking due to tensile stresses which are set up in the magnet body during cooling of the magnet after the extrusion process. During the extrusion process, a magnet body, which typically is comprised of neodymium-iron-cobalt-boron-gallium (NdFeCoBGa) or prasedymium-iron-cobalt-copper-boron-gallium (PrFeCoCuBGa) alloys, bonds with the container involved in the extrusion process—typically a cylindrical steel can. The coefficient of thermal expansion between the container and the magnet charge are at variance such that the aforementioned tensile stresses are created. During cooling, these stresses result in cracking of the finished product which, in turn, has prevented the use of this process to be used commercially. Further, magnets produced through the extrusion processes of the prior art have lacked enhanced magnetic properties of similar magnets produced by other means. [0004]
    • SUMMARY OF THE INVENTION
  • It is the purpose of the present invention, therefore, to provide an improved method for producing an anisotropic magnet through extrusion which reduces the tensile stresses that result in cracking of the finished product. An additional object of this invention is to provide an improved method for producing anisotropic magnet bodies wherein the internal surface of the container involved in the extrusion process is lined with a material to prevent the bonding of the container to the magnet charge and reduce resultant tensile stresses which are created during cooling. Several materials may be used for this coating, including inert materials such as fused silica, high temperature refractory cement and boron nitride. These materials may be applied as a paste or spray. In a preferred embodiment, boron nitride provides a smooth surface on the final magnetic body. Other possible coating materials include zirconia, yttria, ceria and other rare earth oxides and their combinations. [0005]
  • The improved extrusion process described by this invention has direct application to the production of NdFeB anisotropic magnets. Additionally, the improved extrusion process described by this invention may be used to fabricate hexagonal ferrite magnets (i.e., barium, strontium and lanthanum ferrites) and provide high energy products in the range 2-5 MG Oe and, also, samarium—iron nitrides of the composition Sm[0006] 2Fe17Nx and MnBi magnets.
  • It is the further object of this invention to provide an improved method for producing an anisotropic magnet body through an extrusion process wherein the extrusion product is subjected to a post-extrusion thermal treatment to improve and enhance the permanent magnet properties such as remanence, coercivity and energy product. In particular, the post-extrusion thermal treatment consists of holding the extrusion product at temperatures from 1000° F. to 1750° F. for 1 to 10 hours.[0007]
    • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • It is known in the prior art to produce anisotropic magnets through an extrusion process whereby a particle charge of the desired permanent magnet alloy is placed in a container, the container is sealed and heated (along with the charge) and extruded to achieve a magnet having crystal alignment and full density. An example of the prior art in this regard is Chandhok et al. Unfortunately, and as discussed above, the finished product resulting from this methodology has yet to be used commercially because of tensile stresses and cracking which result in this extruded magnet body. Such tensile stresses and related cracking occur because of variances between the coefficient of thermal expansion between the container involved in the extrusion process and the magnetic alloy. More specifically, the charge and resulting magnetic body bond with the container during the extrusion process and, upon cooling after the extrusion process, temperature tensile stresses are set up in the magnetic body which result in cracks. [0008]
  • The above-described tensile stresses, and resulting cracks in the finished magnetic body, can be prevented through use of a coating on the internal surface of the container involved in the extrusion process. More specifically, in accordance with one embodiment of the invention, the container involved in the extrusion process can be coated with a material to prevent the bonding of the interior surface of the container to the charge and resulting magnetic body. Preferably, the coating is comprised of an inert material from the group consisting of fused silica, high temperature refractory cement and boron nitride. These materials may be applied as a paste or spray. In a preferred embodiment of the present invention, boron nitride is used as the coating because it produces a final magnetic body which has a smoother surface. Additionally, the coating of the internal surface of the container involved in the extrusion process can also be comprised of the group consisting of zirconia, yttria, ceria and other rare earth oxides and their combinations. [0009]
  • This improved extrusion process has, in a preferred embodiment, application to Nd(Fe,Co) (B,Ga) magnets. However, this improved extrusion process is also applicable to fabrication of hexagonal ferrites (i.e., barium, strontium and lanthanum ferrites) and, in particular, hexagonal ferrites that produce high energy products in the range of 2-5 MG Oe and Sm[0010] 2Fe17Nx and MnBi magnets.
  • Additionally, the magnetic properties of an extruded anisotropic magnet can be improved or enhanced through a post-extrusion thermal treatment. More specifically, in accordance with another embodiment of the present invention, the extrusion product, i.e. the resulting magnetic body, can be subjected to a post-extrusion thermal treatment which consists of holding the extrusion product at temperatures from between 1000° F. to 1750° F. for several hours. Through this post-extrusion treatment, enhanced magnetic properties such as remanence, coercivity and energy product are achieved. [0011]

Claims (9)

What is claimed is:
1. A method for producing an improved anisotropic magnet, said method comprising placing a particle charge of a composition from which said magnet is to be produced in a container, evacuating and sealing said container, heating said container and said particle charge and extruding said container and particle charge, wherein said container, prior to introduction of said particle charge, is coated on the internal surface of said container with a material to prevent the bonding of said interior surface of said container to said particle charge and, thereby, to prevent cracking due to tensile stresses.
2. The method of claim 1 wherein said material is an inert material selected from the group consisting of fused silica, high temperature refractory cement and boron nitride.
3. The method of claim 1 wherein said material is an inert material selected from the group consisting of zirconia, yttria, ceria, other rare earth oxides and combinations of zirconia, yttria, ceria and other rare earth oxides.
4. The method of claim 1 wherein said coating is applied as a paste.
5. The method of claim 1 wherein said coating is applied as a spray.
6. The method of claim 1 wherein said method further includes the step of subjecting the post extrusion product to a thermal treatment which consists of holding the temperature of said extrusion product at temperatures between 1000° F. and 1750° F. to obtain enhanced magnetic properties.
7. The method of claim 6 wherein said thermal treatment is applied for between 1 and 10 hours.
8. A method for producing an improved anisotropic magnet with enhanced magnetic properties, said method comprising placing a particle charge of a composition from which said magnet is to be produced in a container, evacuating and sealing said container, heating said container and said particle charge, extruding said container and particle charge, and subjecting the post extrusion product to a thermal treatment which consists of holding the temperature of said extrusion product at temperatures between 1000° F. and 1750° F.
9. The method of claim 8 wherein said thermal treatment is applied for between 1 and 10 hours.
US10/275,221 2001-03-09 2001-03-09 Method for producing improved an anisotropic magent through extrusion Abandoned US20030211000A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
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US10/275,221 US20030211000A1 (en) 2001-03-09 2001-03-09 Method for producing improved an anisotropic magent through extrusion
PCT/US2001/007560 WO2001083128A1 (en) 2000-05-04 2001-03-09 Method for producing an improved anisotropic magnet through extrusion

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9818516B2 (en) 2014-09-25 2017-11-14 Ford Global Technologies, Llc High temperature hybrid permanent magnet
US11948733B2 (en) 2020-01-17 2024-04-02 Ford Global Technologies, Llc Processing of anisotropic permanent magnet without magnetic field

Citations (24)

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Publication number Priority date Publication date Assignee Title
US4325757A (en) * 1979-09-04 1982-04-20 General Motors Corporation Method of forming thin curved rare earth-transition metal magnets from lightly compacted powder preforms
US4439236A (en) * 1979-03-23 1984-03-27 Allied Corporation Complex boride particle containing alloys
US4732622A (en) * 1985-10-10 1988-03-22 United Kingdom Atomic Energy Authority Processing of high temperature alloys
US4869869A (en) * 1987-09-25 1989-09-26 Ceracon, Inc. Method of consolidating FeNdB magnets
US4881984A (en) * 1986-07-28 1989-11-21 Crucible Materials Corporation Consolidation of magnet alloy powders by extrusion and product therefrom
US4895607A (en) * 1988-07-25 1990-01-23 Kubota, Ltd. Iron-neodymium-boron permanent magnet alloys prepared by consolidation of amorphous powders
US4971756A (en) * 1989-05-12 1990-11-20 Crucible Materials Corporation Method for producing dies for use in compacting permanent magnet alloy powders
US5056209A (en) * 1988-12-09 1991-10-15 Sumitomo Metal Industries, Ltd. Process for manufacturing clad metal tubing
US5093076A (en) * 1991-05-15 1992-03-03 General Motors Corporation Hot pressed magnets in open air presses
US5121535A (en) * 1988-12-14 1992-06-16 Sulzer Bros. Ltd. Method for production of thin sections of reactive metals
US5129963A (en) * 1990-05-16 1992-07-14 General Motors Corporation Rare earth magnet alloys with excellent hot workability
US5178691A (en) * 1990-05-29 1993-01-12 Matsushita Electric Industrial Co., Ltd. Process for producing a rare earth element-iron anisotropic magnet
US5250255A (en) * 1990-11-30 1993-10-05 Intermetallics Co., Ltd. Method for producing permanent magnet and sintered compact and production apparatus for making green compacts
US5277831A (en) * 1991-03-06 1994-01-11 Hanano Commercial Co., Ltd. Method for low pressure die casting with low pressure die casting powdery mold releasing agent
US5301403A (en) * 1992-05-08 1994-04-12 Gebrueder Sulzer Aktiengesellschaft Method of producing metal foil from a reactive metal sheet utilizing a hot rolling thermal pack assembly
US5316203A (en) * 1993-04-27 1994-05-31 General Electric Company Encapsulated stop-off coating for diffusion bonding
US5443787A (en) * 1993-07-13 1995-08-22 Tdk Corporation Method for preparing iron system soft magnetic sintered body
US5540882A (en) * 1992-11-16 1996-07-30 Erasteel Kloster Aktiebolag Method relating to powder metallurgical manufacturing of a body
US5564064A (en) * 1995-02-03 1996-10-08 Mcdonnell Douglas Corporation Integral porous-core metal bodies and in situ method of manufacture thereof
US5672363A (en) * 1990-11-30 1997-09-30 Intermetallics Co., Ltd. Production apparatus for making green compact
US5819572A (en) * 1997-07-22 1998-10-13 General Motors Corporation Lubrication system for hot forming
US6183571B1 (en) * 1994-10-06 2001-02-06 Akihisa Inoue Permanent magnetic material and permanent magnet
US6273963B1 (en) * 1992-02-10 2001-08-14 Iap Research, Inc. Structure and method for compaction of powder-like materials
US6372348B1 (en) * 1998-11-23 2002-04-16 Hoeganaes Corporation Annealable insulated metal-based powder particles

Patent Citations (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4439236A (en) * 1979-03-23 1984-03-27 Allied Corporation Complex boride particle containing alloys
US4325757A (en) * 1979-09-04 1982-04-20 General Motors Corporation Method of forming thin curved rare earth-transition metal magnets from lightly compacted powder preforms
US4732622A (en) * 1985-10-10 1988-03-22 United Kingdom Atomic Energy Authority Processing of high temperature alloys
US4881984A (en) * 1986-07-28 1989-11-21 Crucible Materials Corporation Consolidation of magnet alloy powders by extrusion and product therefrom
US4869869A (en) * 1987-09-25 1989-09-26 Ceracon, Inc. Method of consolidating FeNdB magnets
US4895607A (en) * 1988-07-25 1990-01-23 Kubota, Ltd. Iron-neodymium-boron permanent magnet alloys prepared by consolidation of amorphous powders
US5056209A (en) * 1988-12-09 1991-10-15 Sumitomo Metal Industries, Ltd. Process for manufacturing clad metal tubing
US5121535A (en) * 1988-12-14 1992-06-16 Sulzer Bros. Ltd. Method for production of thin sections of reactive metals
US4971756A (en) * 1989-05-12 1990-11-20 Crucible Materials Corporation Method for producing dies for use in compacting permanent magnet alloy powders
US5129963A (en) * 1990-05-16 1992-07-14 General Motors Corporation Rare earth magnet alloys with excellent hot workability
US5178691A (en) * 1990-05-29 1993-01-12 Matsushita Electric Industrial Co., Ltd. Process for producing a rare earth element-iron anisotropic magnet
US5250255A (en) * 1990-11-30 1993-10-05 Intermetallics Co., Ltd. Method for producing permanent magnet and sintered compact and production apparatus for making green compacts
US5672363A (en) * 1990-11-30 1997-09-30 Intermetallics Co., Ltd. Production apparatus for making green compact
US5277831A (en) * 1991-03-06 1994-01-11 Hanano Commercial Co., Ltd. Method for low pressure die casting with low pressure die casting powdery mold releasing agent
US5093076A (en) * 1991-05-15 1992-03-03 General Motors Corporation Hot pressed magnets in open air presses
US6273963B1 (en) * 1992-02-10 2001-08-14 Iap Research, Inc. Structure and method for compaction of powder-like materials
US5301403A (en) * 1992-05-08 1994-04-12 Gebrueder Sulzer Aktiengesellschaft Method of producing metal foil from a reactive metal sheet utilizing a hot rolling thermal pack assembly
US5540882A (en) * 1992-11-16 1996-07-30 Erasteel Kloster Aktiebolag Method relating to powder metallurgical manufacturing of a body
US5316203A (en) * 1993-04-27 1994-05-31 General Electric Company Encapsulated stop-off coating for diffusion bonding
US5443787A (en) * 1993-07-13 1995-08-22 Tdk Corporation Method for preparing iron system soft magnetic sintered body
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US5564064A (en) * 1995-02-03 1996-10-08 Mcdonnell Douglas Corporation Integral porous-core metal bodies and in situ method of manufacture thereof
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US6372348B1 (en) * 1998-11-23 2002-04-16 Hoeganaes Corporation Annealable insulated metal-based powder particles

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9818516B2 (en) 2014-09-25 2017-11-14 Ford Global Technologies, Llc High temperature hybrid permanent magnet
US11948733B2 (en) 2020-01-17 2024-04-02 Ford Global Technologies, Llc Processing of anisotropic permanent magnet without magnetic field

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