US2121799A - Process for making cast permanent magnets - Google Patents
Process for making cast permanent magnets Download PDFInfo
- Publication number
- US2121799A US2121799A US151029A US15102937A US2121799A US 2121799 A US2121799 A US 2121799A US 151029 A US151029 A US 151029A US 15102937 A US15102937 A US 15102937A US 2121799 A US2121799 A US 2121799A
- Authority
- US
- United States
- Prior art keywords
- crucible
- aluminum
- parts
- mixture
- nickel
- 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.)
- Expired - Lifetime
Links
- 238000000034 method Methods 0.000 title description 13
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 28
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 24
- 239000000203 mixture Substances 0.000 description 18
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 16
- 229910052782 aluminium Inorganic materials 0.000 description 14
- 229910045601 alloy Inorganic materials 0.000 description 13
- 239000000956 alloy Substances 0.000 description 13
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 12
- 229910052759 nickel Inorganic materials 0.000 description 12
- 239000002893 slag Substances 0.000 description 12
- 238000004519 manufacturing process Methods 0.000 description 11
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 9
- 238000006243 chemical reaction Methods 0.000 description 8
- 238000005266 casting Methods 0.000 description 7
- 239000007788 liquid Substances 0.000 description 7
- 229910052799 carbon Inorganic materials 0.000 description 6
- 229910052742 iron Inorganic materials 0.000 description 6
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 4
- 229910001004 magnetic alloy Inorganic materials 0.000 description 4
- 229910002804 graphite Inorganic materials 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
- 229910001338 liquidmetal Inorganic materials 0.000 description 3
- 239000011230 binding agent Substances 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000010891 electric arc Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- XEEYBQQBJWHFJM-RNFDNDRNSA-N iron-60 Chemical compound [60Fe] XEEYBQQBJWHFJM-RNFDNDRNSA-N 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000003110 molding sand Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
Definitions
- This invention relates to cast permanent magnets and more'partlcularly to a new process for their fabrication.
- This invention relates particularly to the vari 'ous new magnet alloys containing iron, nickel, aluminum and other ingredients in vary percentages.
- One of the important objects of this invention is the provision of a simple, economical method of producing cast alloys which can be later readily magnetized and which, on account of the I method of manufacture, will acquire and possess a highdegree of magnetic power.
- a further object of the invention is the provision of a magnetic alloy which eliminates the necessity of annealingor aging so far as the final product is concerned, particularly inthat the super-heating, which accompanies the process of manufacture, produces a product which, when cooled, is practically automatically normalized.
- My new process permits the making of cast magnets cheaply; and quickly, either in the shop or laboratory, without theme of a furnace or the conventional molding equipment necessary in a foundry where small castings are made.
- the combustion is started by igniting a the-mixture at one spot and continues throughout the entire mass without the use of any other heating agency and results in super heated liquid iron and slag.
- the completereaction is completed in less than one half minute, creating a temperature in the neighborhood of 5000 F.
- the liquid iron produced represents one half of the original mixture by weight and one third by volume.
- the foregoing chemical reaction was first observed in 1857 by Friederich Woehler, the discoverer of aluminum.
- the cast material may be magnetized in a suitable manner either in one piece or after having been cut or broken into separate parts. Further machining, shaping and finishing may also be accomplished either before or after magnetizing.
- Cores and even parts of the mold can also be made of a mixture consisting of graphite one part and fine molding sand, two parts, with any good core binder. I fire all core and mold parts to remove water and carbonize. the binder; I
- the liquid slag which will not mix with the metal and evidently has a higher melting point, freezes or solidifies in a thin strata on the sides of the still relatively cool crucible so that when the thermic action is completed, the liquid metal is easily poured out of the crucible, there being absolutely no slag in the pour.
- the layer of slag clinging to the sides and bottom of the crucible will drop out by simply inverting the crucible. It may sometimes be necessary to tap the bottom of the crucible with a wooden mallet. In all cases, the slag formation drops out in a one-piece cup shape.
- a permanent magnet alloy consisting substantially of mixing by weight 30 to 50 parts iron oxide, 10 to 20 parts aluminum parts of flake iron oxide, to 25 parts of shotted aluminum, and 2 to 20 parts of shotted nickel, igniting said mixture in a crucible, whirling the crucible to cause slag to solidify on sides of crucible, and pouring resultant liquid metal into a carbon mold immediately after chemical action is completed.
- a method of making a magnetic alloy comprising mixing fiake iron oxide, aluminum and nickel in a crucible, igniting the mixture, centrifuging out the slag while the thermic reaction is taking place and pouring the molten metal into molds.
- a method of making a magnetic alloy comprising mixing iron oxide, aluminum and nickel in acrucible in such proportions as to yield a final composition containing approximately iron 60%, nickel 30%, and aluminum 10%, igniting the mixture, separating the liquid from the slag by centrifugal action and pouring the molten metal into molds.
- a method of making a magnetic alloy comprising mixing iron oxide, aluminum and nickel in a crucible in such proportions as to yield a final composition containing approximately iron 50 to 70%, nickel 20 to 40%, and aluminum 8 to 15%, igniting the mixture, centrifuging out the slag and pouring the molten metal into molds.
Description
Patented June 28,
PROCESS FOR MAKING OAST PERMANENT 'MAGNETS Hugh A. HowelL-Berwyn, 111., animal to es, Chicago. Ill.
No Application June 29, 1937,
' Serial No.1 51,029
8 Claims. (01. 15-27) This invention relates to cast permanent magnets and more'partlcularly to a new process for their fabrication.
It is one of the objects of the present invention tov provide a method of making castv magnets easily and cheaply without resource to orthodox foundry methods, materials and equipment.
This invention relates particularly to the vari 'ous new magnet alloys containing iron, nickel, aluminum and other ingredients in vary percentages.
One of the important objects of this invention is the provision of a simple, economical method of producing cast alloys which can be later readily magnetized and which, on account of the I method of manufacture, will acquire and possess a highdegree of magnetic power.
A further object of the invention is the provision of a magnetic alloy which eliminates the necessity of annealingor aging so far as the final product is concerned, particularly inthat the super-heating, which accompanies the process of manufacture, produces a product which, when cooled, is practically automatically normalized.
My new process permits the making of cast magnets cheaply; and quickly, either in the shop or laboratory, without theme of a furnace or the conventional molding equipment necessary in a foundry where small castings are made.
The new features which I believe to be characteristic of my invention are set forth in the followingspeciflcations and particularly in the appended claims. 7
My invention will be best understood from a reference to the well-known chemical reaction between iron oxide and aluminum based on .the equation FezOa+2Al=2Fe+Ala0a Iron oxide and metallic aluminum in a properly divided state, mixed inabout the proportions of the foregoing equation, will react when properly ignited in such a way that the oxygen in the iron oxide is released and combines with the metallic aluminum to form aluminum oxide or slag, setting free the iron. The combustion is started by igniting a the-mixture at one spot and continues throughout the entire mass without the use of any other heating agency and results in super heated liquid iron and slag. The completereaction is completed in less than one half minute, creating a temperature in the neighborhood of 5000 F. The liquid iron produced represents one half of the original mixture by weight and one third by volume. The foregoing chemical reaction was first observed in 1857 by Friederich Woehler, the discoverer of aluminum.
In fabricating magnet alloys with my new process, I mix iron oxide in the proper physical state with aluminum, nickel or other metals in a divided and commercially pure state in an ordinary graphite crucible. I ignite this mixture with a small electric arc produced in any convenient manner. While the chemical reaction is taking place, Iagitat the mixture by rocking and twirling the crucible, while holding in an upright position in order to cause the superheated slagto freeze or adhere to the sides of the crucible. After the reaction has beencompleted, and before the liquid iron has had time to solidify, I pour all but the slag into an unheated carbon mold built up of several parts. Immediately after the casting has solidified, I remove it from the mold to cool naturally in the open air.
The cast material may be magnetized in a suitable manner either in one piece or after having been cut or broken into separate parts. Further machining, shaping and finishing may also be accomplished either before or after magnetizing.
I make my molds of pre-fabricated carbon sections, the number of sections depending upon the size and shape of the magnet and the amount of detail desired.
Cores and even parts of the mold can also be made of a mixture consisting of graphite one part and fine molding sand, two parts, with any good core binder. I fire all core and mold parts to remove water and carbonize. the binder; I
' have made as high as one hundred castings from Parts byweight. Iron oxide (scale)approximate1y 40 Fine commercially pure aluminum shot-approximately 15 Fine nickel shot-approximately 10 with above mixture and variations of same, I have poured castings weighing as little as five 50 grams, the only equipment necessary being a pair of tongs, a small crucible and a suitable igniting device.
With a mixture consisting of 40 grams of. iron oxide, 15.grams of aluminum shot and lo grams I the magnetic properties of the nickel-aluminumiron family of alloys. In fact, others have claimed that the addition of a certain amount of cobalt, chromium, copper, vanadium or manganese, etc. gives improved characteristics to the alloys.
I have not observed any marked improvement by special heat treatment of magnets made by my method, therefore heat treatment does not form a part of my process. I
The mixture described, consisting of about 40 grams of flake iron oxide, 15 grams of shotted aluminum and lograms of nickel will, after the chemical reaction is completed, produce about 35 grams of magnet alloy with approximately the following analysis and characteristics:
It will be noted that when the crucible is whirled, the liquid slag, which will not mix with the metal and evidently has a higher melting point, freezes or solidifies in a thin strata on the sides of the still relatively cool crucible so that when the thermic action is completed, the liquid metal is easily poured out of the crucible, there being absolutely no slag in the pour. After the crucible has cooled to about 400 F. or lower, the layer of slag clinging to the sides and bottom of the crucible will drop out by simply inverting the crucible. It may sometimes be necessary to tap the bottom of the crucible with a wooden mallet. In all cases, the slag formation drops out in a one-piece cup shape.
It will also be observed that the cooled magnet alloy will, under practically all conditions, retain a silvery white 'untarnished finish, especially if carbon molds are used. The accuracy of castings seems to be limited only by the design and tolerances in the mold.
Alloys, when made with this process and poured soon enough after the chemical reaction is completed, will be. superheated and very liquid, as comparedwith ordinary foundry practice. I have filled in cavities in carbon molds resulting in fins over one inch square and less than .010 inch thick-proving the fluidity of alloy.
, I am aware that many changes may be made in the ingredients and numerous details in the process varied throughout a wide range without departing from the principles of thisinvention, and I, therefore, do not purpose limiting the patent granted hereon otherwise than as necessitated by the prior art.
What I claim as new in the fabrication of permanent magnet alloys and desire to secure by Letters Patent of the United states is:
l. The method of making a permanent magnet alloy consisting substantially of mixing by weight 30 to 50 parts iron oxide, 10 to 20 parts aluminum parts of flake iron oxide, to 25 parts of shotted aluminum, and 2 to 20 parts of shotted nickel, igniting said mixture in a crucible, whirling the crucible to cause slag to solidify on sides of crucible, and pouring resultant liquid metal into a carbon mold immediately after chemical action is completed.
3. The method of making a permanent magnet alloy consisting substantially of mixing by weight 30 to 50 parts of flake iron oxide, to 20 parts of fine shotted aluminum and 5 to parts of fine shotted nickel; pouring this mixture 'in a graphite crucible and igniting said mixture; agitating with a whirling motion during chemical reaction tofreeze liquid'slag to sides of crucible and pouring resultant liquid metal into a carbon mold after combustion is completed, removing the solidified casting 'and allowed to cool in air.
4. The method of making a permanent magnet alloy consisting substantially of 30 to 50 parts of iron oxide and 10-20 parts nickel and 10-20 the, sides of the crucible, and then magnetizing the casting.
6. A method of making a magnetic alloy, comprising mixing fiake iron oxide, aluminum and nickel in a crucible, igniting the mixture, centrifuging out the slag while the thermic reaction is taking place and pouring the molten metal into molds.
7. A method of making a magnetic alloy, comprising mixing iron oxide, aluminum and nickel in acrucible in such proportions as to yield a final composition containing approximately iron 60%, nickel 30%, and aluminum 10%, igniting the mixture, separating the liquid from the slag by centrifugal action and pouring the molten metal into molds.
8. A method of making a magnetic alloy, comprising mixing iron oxide, aluminum and nickel in a crucible in such proportions as to yield a final composition containing approximately iron 50 to 70%, nickel 20 to 40%, and aluminum 8 to 15%, igniting the mixture, centrifuging out the slag and pouring the molten metal into molds.
HUGH A. HOWELL.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US151029A US2121799A (en) | 1937-06-29 | 1937-06-29 | Process for making cast permanent magnets |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US151029A US2121799A (en) | 1937-06-29 | 1937-06-29 | Process for making cast permanent magnets |
Publications (1)
Publication Number | Publication Date |
---|---|
US2121799A true US2121799A (en) | 1938-06-28 |
Family
ID=22537037
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US151029A Expired - Lifetime US2121799A (en) | 1937-06-29 | 1937-06-29 | Process for making cast permanent magnets |
Country Status (1)
Country | Link |
---|---|
US (1) | US2121799A (en) |
-
1937
- 1937-06-29 US US151029A patent/US2121799A/en not_active Expired - Lifetime
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