WO2005023464A1 - Iron based soft magnetic powder - Google Patents
Iron based soft magnetic powder Download PDFInfo
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- WO2005023464A1 WO2005023464A1 PCT/SE2004/001296 SE2004001296W WO2005023464A1 WO 2005023464 A1 WO2005023464 A1 WO 2005023464A1 SE 2004001296 W SE2004001296 W SE 2004001296W WO 2005023464 A1 WO2005023464 A1 WO 2005023464A1
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 title claims abstract description 37
- 229910052742 iron Inorganic materials 0.000 title description 9
- 239000006247 magnetic powder Substances 0.000 title description 3
- 239000000843 powder Substances 0.000 claims abstract description 90
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 26
- 239000001301 oxygen Substances 0.000 claims abstract description 26
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 26
- 239000012535 impurity Substances 0.000 claims abstract description 16
- 239000002131 composite material Substances 0.000 claims abstract description 12
- 238000004438 BET method Methods 0.000 claims abstract description 5
- 238000002360 preparation method Methods 0.000 claims abstract description 4
- 239000002245 particle Substances 0.000 claims description 39
- 238000000576 coating method Methods 0.000 claims description 23
- 238000000034 method Methods 0.000 claims description 18
- 239000011248 coating agent Substances 0.000 claims description 17
- 238000000137 annealing Methods 0.000 claims description 16
- 239000000314 lubricant Substances 0.000 claims description 13
- 239000000203 mixture Substances 0.000 claims description 8
- 239000011230 binding agent Substances 0.000 claims description 7
- 238000010438 heat treatment Methods 0.000 claims description 7
- 238000005056 compaction Methods 0.000 claims description 6
- 229910052698 phosphorus Inorganic materials 0.000 claims description 4
- 238000005461 lubrication Methods 0.000 claims description 3
- 239000004610 Internal Lubricant Substances 0.000 claims description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 2
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims 3
- 239000011574 phosphorus Substances 0.000 claims 3
- 238000002156 mixing Methods 0.000 claims 1
- 239000000306 component Substances 0.000 description 16
- 239000011162 core material Substances 0.000 description 14
- 230000035699 permeability Effects 0.000 description 11
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 8
- 238000009826 distribution Methods 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- 229910019142 PO4 Inorganic materials 0.000 description 6
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 6
- 239000010452 phosphate Substances 0.000 description 6
- 230000000694 effects Effects 0.000 description 5
- 238000005259 measurement Methods 0.000 description 5
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 4
- 239000008358 core component Substances 0.000 description 4
- 230000004907 flux Effects 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- 229910052757 nitrogen Inorganic materials 0.000 description 4
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 3
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 description 3
- 239000001257 hydrogen Substances 0.000 description 3
- 229910052739 hydrogen Inorganic materials 0.000 description 3
- 239000000696 magnetic material Substances 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 238000010292 electrical insulation Methods 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 239000010410 layer Substances 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- RKISUIUJZGSLEV-UHFFFAOYSA-N n-[2-(octadecanoylamino)ethyl]octadecanamide Chemical compound CCCCCCCCCCCCCCCCCC(=O)NCCNC(=O)CCCCCCCCCCCCCCCCC RKISUIUJZGSLEV-UHFFFAOYSA-N 0.000 description 2
- 239000011368 organic material Substances 0.000 description 2
- 239000003960 organic solvent Substances 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000009692 water atomization Methods 0.000 description 2
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical class [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 2
- 239000004605 External Lubricant Substances 0.000 description 1
- 229910000576 Laminated steel Inorganic materials 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000003677 Sheet moulding compound Substances 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000002156 adsorbate Substances 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 238000000748 compression moulding Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 229910000398 iron phosphate Inorganic materials 0.000 description 1
- WBJZTOZJJYAKHQ-UHFFFAOYSA-K iron(3+) phosphate Chemical compound [Fe+3].[O-]P([O-])([O-])=O WBJZTOZJJYAKHQ-UHFFFAOYSA-K 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- HGPXWXLYXNVULB-UHFFFAOYSA-M lithium stearate Chemical compound [Li+].CCCCCCCCCCCCCCCCCC([O-])=O HGPXWXLYXNVULB-UHFFFAOYSA-M 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
- 239000006249 magnetic particle Substances 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000005022 packaging material Substances 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920001601 polyetherimide Polymers 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000004663 powder metallurgy Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/33—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials mixtures of metallic and non-metallic particles; metallic particles having oxide skin
-
- 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
- B22F1/16—Metallic particles coated with a non-metal
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/147—Alloys characterised by their composition
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
- H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
- H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
-
- 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
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
-
- 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
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12014—All metal or with adjacent metals having metal particles
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12014—All metal or with adjacent metals having metal particles
- Y10T428/12028—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
- Y10T428/12049—Nonmetal component
- Y10T428/12056—Entirely inorganic
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12181—Composite powder [e.g., coated, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
- Y10T428/2991—Coated
Definitions
- the present invention relates to new soft magnetic composite powder and a new soft magnetic powder for producing the composite powder. More specifically, the invention concerns a new iron-based powder which is useful for the preparation of soft magnetic materials having improved properties when used both at high and low frequencies. The invention also concerns a method for the manufacturing of soft magnetic composite components of the new powder.
- Soft magnetic materials are used for applications, such as core materials in inductors, stators and rotors for electrical machines, actuators, sensors and transformer cores.
- soft magnetic cores such as rotors and stators in electric machines, are made of stacked steel laminates.
- Soft Magnetic Composite, SMC materials are based on soft magnetic particles, usually iron- based, with an electrically insulating coating on each particle. By compacting the insulated particles optionally together with lubricants and or binders using the traditionally powder metallurgy process, the SMC parts are obtained.
- the magnetic permeability of a material is an indication of its ability to become magnetised or its ability to carry a magnetic flux. Permeability is defined as the ratio of the induced magnetic flux to the magnetising force or field intensity.
- Desired component properties include e.g. a high permeability through an extended frequency range, low core losses, high saturation induction, and high strength. Normally an increased density of the component enhances all of these properties.
- the desired powder properties include suitability for compression moulding techniques, which i.e. means that the powder can be easily moulded to a high density component, which can be easily ejected from the moulding equipment.
- the present invention is based on the discovery that unexpected advantages can be obtained depending on the nature of the base powder i.e. the powder, the particles of which are not coated or electrically insulated. Especially unexpected is the finding that a more pure base powder increases the resistivity (decreases the eddy current loss) of the final soft magnetic component. It has thus been found that the permeability and total loss can be remarkably improved by using as a base powder a powder which is very pure, has a low oxygen content and a low specific surface.
- the powder according to the present invention is a high purity, annealed iron powder consisting of base particles surrounded by an electrically insulating coating.
- the base powder is distinguished by a content of inevitable impurities, which is less than 0.30 %, an oxygen content which is less than 0.05 % and a specific surface area as measured by the BET method which is less than 60 m /kg.
- the specific surface area of the particles is a distinguishing feature.
- the specific surface area of the particles depends on the particle size distribution, the particle shape and the roughness of the particles.
- the occurrence of so called open porosity of the particles will also have an impact on the specific surface area.
- the specific surface area is normally measured by the so-called BET method and the result is expressed in m 2 /kg.
- the surface area of granulated and powdered solids or porous material is measured by determining the quantity of gas that absorbs as a single layer of molecules a so called monomolecular layer on a sample. This adsorption is done at or near the boiling point of the adsorbate gas. Under specific conditions the area covered by each gas molecule is known within relatively narrow limits.
- the area of the sample is thus calculable directly from the number of adsorbed molecules, which is derived from the gas quantity at the prescribed conditions and occupied by each.
- the conditions most favourable for the formation of a monolayer of adsorbed nitrogen are establish at atmospheric pressure and the temperature of liquid nitrogen. The method should give an error less then 5 % of measured result.
- the specific surface area should be less than about 60 m /kg.
- the specific surface area of the powder is less than 58, more preferably less than 55 m /kg.
- a specific surface area less than 10 m 2 /kg is less suitable as the moulded component will then get a too low strength.
- the particles have an irregular form and are prepared by water atomising.
- the degree of purity is another important feature of the base powder and it has been found that the powder should be very pure and include iron with a total amount of impurities not exceeding 0.30 % of the base powder.
- Preferred are powders having less than 0.25, preferably less than 0.20 % by weight of impurities.
- a base powder having a low amount of impurities may be obtained by using pure steel scrap.
- Impurities that may be present in the base powder are e.g. Cr, Cu, Mn, Ni, P, S, Si, C. Oxygen is not regarded as an impurity in the context of the present invention.
- a sufficiently low oxygen content, less than 0.05 % by weight of the powder may be obtained by annealing the base powder at a temperature and time sufficient for obtaining the low oxygen content.
- the powders according to the invention have an oxygen content less than 0.04 % by weight.
- the annealing temperature may vary between 900°C and 1300°C and the annealing periods may vary depending on the size of the oven, the type of heating, amount of material loaded in the oven etc. Normally used annealing times may vary between 5 and 300, preferably between 10 and
- the annealed base powder is provided with an electrically insulating coating or barrier.
- this coating is a uniform and very thin and of the type described in the US patent US 6348265 which is hereby incorporated by reference.
- Such an insulating coating may be applied on the base powder particles by treating the base powder with phosphoric acid in an organic solvent for a period sufficient to obtain the indicated amounts.
- the concentration of the phosphoric acid in the organic solvent may vary between 0.5 and 50%, preferably between 0.5 and 30%.
- a coating will add oxygen and phosphorous to the iron base powder particles, a chemical analysis of the coated powder will have oxygen and phosphorous contents which are higher than those of the uncoated powder.
- the oxygen content should preferably be at most 0.20 % and phosphorous content at most 0.10 % of the coated powder.
- other types of insulating coatings may be used.
- a thin even coating on an iron powder will have negligible influence on the specific surface area of the coated powder compared with the specific surface area of the base powder. According to the present invention a coating will only to a minor extent influence the specific surface area which means that the specific surface area of the coated iron powder will be more or less the same as the specific surface area of the uncoated iron powder.
- the iron-based powder thus provided with an electrical insulation can be combined with a lubricant in an amount up to 4% by weight.
- the amount of lubricant varies between 0.1 and 2 % by weight, preferably 0.1 - 1.0 % by weight of the powder composition.
- Representative examples of lubricants used at ambient temperatures are: Kenolube®, Ethylene-bis-stearamide (EBS) and metal stearates, such as zinc stearate.
- Representative examples of lubricants used at elevated temperatures (high temperature lubricants) are Promold® or lithium stearate.
- composition to be compacted may also include a binder in order to enhance the strength of the SMC component.
- binders are thermosetting or thermoplastic resins such as phenolic resins, polyether imides, polyamides.
- the binder may have lubricating properties and may then be used alone as a combined lubricant/binder.
- the compacting could be carried out at pressures up to 2000 MPa although normally the pressure varies between 400 and 1000 MPa.
- the compacting could be carried out both at ambient and elevated temperature.
- the compacting operation is preferably performed as an uniaxial pressure moulding operation in a die or as high velocity compaction as described in the US patent 6503444 Die wall lubrication where an external lubricant is applied on the walls of the die could be used for eliminating the need of internal lubricants.
- a combination of internal and external lubrication may be used.
- Oxygen content after annealing O 0.02 0.02 0.02
- Figure 1 shows the effect of the content of impurities other than oxygen in the parent phase of phosphate coated iron powder versus the resisitvity of a moulded and heat- treated body produced from the powder.
- This example demonstrates the effect of the annealing procedure and the oxygen content of the parent phase of phosphate coated iron powder on the resistivty and core losses.
- Three different annealing procedures were applied according to table 2. The three different samples were subjected to a phosphate treatment according to example 1. Three different rings, respectively, were moulded and heat-treated according to example 1. The reached density of the rings were 7,4 g/cm 3 . Resistivity of the components was measured according to example 1.
- the rings were "wired" with 112 turns for the primary circuit and 25 turns for the secondary circuit enabling measurements of magnetic properties measured at 1 T, 400 Hz.with the aid of a hysteresisgraph, Brockhaus MPG 100.
- This example demonstrates the effect of the specific surface, measured by the BET- method, of the annealed atomised iron powder.
- the samples with the same particle size distribution were annealed in an atmosphere of hydrogen at temperatures and annealing times enough to reach an oxygen content of 0.035 % and 0.08 %, respectively, followed by a treatment with a phosphate solution according to example 2.
- the sample with the finer particle size distribution was annealed in an atmosphere of hydrogen at temperatures and annealing times enough to reach an oxygen content of 0.035 %
- Magnetic rings were prepared according to the method described in example 2 and the resistivity, core losses and magnetic permeabi- lity were measured as disclosed in this example. The specific surface and oxygen content were measured after annealing.
- Table 3 shows the result of magnetic measurements and the characteristics of the annealed parent phase of the soft magnetic composite powder.
- Table 3 shows that soft magnetic components prepared from those base powders which have the lowest oxygen content and the lowest specific surface area have superior magnetic properties.
- This example shows the effect on magnetic permeability and resistivity and total core loss for a component produced by the new soft magnetic composite powder compared with a component produced by a known powder disclosed in US patent 6348265.
- both the magnetic permeability and the resistivity are higher and the core loss is lower for the new powder compared with the known powder at the same heat treating temperature.
- the above mentioned findings, illustrated by the examples, disclose an atomised iron powder, suitable for producing soft magnetic composite powder. This powder can be used for producing magnetic cores with a resistivity higher than 40 ⁇ ohm.m, a core loss less than 50 W/kg at 1 T, 400 Hz and a maximum permeability above 600 produced by PM moulding at ambient or elevated temperature and conventional moulding pressures.
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- Power Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
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Abstract
Description
Claims
Priority Applications (10)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
BRPI0413853-8A BRPI0413853B1 (en) | 2003-09-09 | 2004-09-08 | Iron-based malleable magnetic powder, powder composition comprising the same and method of preparing a malleable compound material |
PL04775401T PL1663549T3 (en) | 2003-09-09 | 2004-09-08 | Iron based soft magnetic powder |
AU2004270090A AU2004270090B2 (en) | 2003-09-09 | 2004-09-08 | Iron based soft magnetic powder |
CA2534466A CA2534466C (en) | 2003-09-09 | 2004-09-08 | Iron based soft magnetic powder |
US10/568,952 US7455905B2 (en) | 2003-09-09 | 2004-09-08 | Iron based soft magnetic powder having an insulating coating |
MXPA06002643 MX258741B (en) | 2003-09-09 | 2004-09-08 | Iron based soft magnetic powder. |
DE602004013606T DE602004013606D1 (en) | 2003-09-09 | 2004-09-08 | |
KR1020067004853A KR101097896B1 (en) | 2003-09-09 | 2004-09-08 | Iron based soft magnetic powder |
EP04775401A EP1663549B1 (en) | 2003-09-09 | 2004-09-08 | Iron based soft magnetic powder |
JP2006526044A JP4880462B2 (en) | 2003-09-09 | 2004-09-08 | Iron-based soft magnetic powder |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
SE0302427A SE0302427D0 (en) | 2003-09-09 | 2003-09-09 | Iron based soft magnetic powder |
SE0302427-0 | 2003-09-09 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2005023464A1 true WO2005023464A1 (en) | 2005-03-17 |
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ID=28787309
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/SE2004/001296 WO2005023464A1 (en) | 2003-09-09 | 2004-09-08 | Iron based soft magnetic powder |
Country Status (18)
Country | Link |
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US (1) | US7455905B2 (en) |
EP (1) | EP1663549B1 (en) |
JP (2) | JP4880462B2 (en) |
KR (1) | KR101097896B1 (en) |
CN (1) | CN100439012C (en) |
AT (1) | ATE394187T1 (en) |
AU (1) | AU2004270090B2 (en) |
BR (1) | BRPI0413853B1 (en) |
CA (1) | CA2534466C (en) |
DE (1) | DE602004013606D1 (en) |
ES (1) | ES2305851T3 (en) |
MX (1) | MX258741B (en) |
PL (1) | PL1663549T3 (en) |
RU (1) | RU2311261C2 (en) |
SE (1) | SE0302427D0 (en) |
TW (1) | TWI289487B (en) |
WO (1) | WO2005023464A1 (en) |
ZA (1) | ZA200601216B (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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EP1716946A1 (en) * | 2004-01-30 | 2006-11-02 | Sumitomo Electric Industries, Ltd. | Soft magnetic material and dust core |
EP2147445A2 (en) * | 2006-12-07 | 2010-01-27 | Höganäs AB | Soft magnetic powder |
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US20070241063A1 (en) * | 2006-04-18 | 2007-10-18 | Quebec Metal Powders Ltd. | Process for treating water using atomized ferrous powders containing 0.25 to 4 wt% carbon and 1 to 6 wt% oxygen |
RU2510993C2 (en) * | 2008-03-20 | 2014-04-10 | Хеганес Аб (Пабл) | Powdered ferromagnetic composition and method for production thereof |
MX2011005520A (en) * | 2008-11-26 | 2011-06-16 | Hoeganaes Ab Publ | Lubricant for powder metallurgical compositions. |
WO2011040568A1 (en) * | 2009-09-30 | 2011-04-07 | 日立粉末冶金株式会社 | Process for producing dust core |
JP5482097B2 (en) * | 2009-10-26 | 2014-04-23 | Tdk株式会社 | Soft magnetic material, dust core and method for manufacturing the same |
JP2011094204A (en) * | 2009-10-30 | 2011-05-12 | Tdk Corp | Surface-treated reduced iron powder, method for producing the same, and powder magnetic core |
JP6026889B2 (en) * | 2010-02-18 | 2016-11-16 | ホガナス アクチボラゲット | Ferromagnetic powder composition and method for producing the same |
JP5438669B2 (en) * | 2010-12-28 | 2014-03-12 | 株式会社神戸製鋼所 | Iron-based soft magnetic powder for dust core and dust core |
JP6052960B2 (en) * | 2012-01-12 | 2016-12-27 | 株式会社神戸製鋼所 | Method for producing soft magnetic iron-based powder |
KR102023112B1 (en) | 2013-04-19 | 2019-09-19 | 제이에프이 스틸 가부시키가이샤 | Iron powder for dust core and insulation-coated iron powder for dust core |
JP6609255B2 (en) * | 2013-12-20 | 2019-11-20 | ホガナス アクチボラグ (パブル) | Soft magnetic powder mixture |
KR101686989B1 (en) * | 2014-08-07 | 2016-12-19 | 주식회사 모다이노칩 | Power Inductor |
KR101662206B1 (en) | 2014-08-07 | 2016-10-06 | 주식회사 모다이노칩 | Power inductor |
KR101662207B1 (en) | 2014-09-11 | 2016-10-06 | 주식회사 모다이노칩 | Power inductor |
JP6757117B2 (en) * | 2014-10-02 | 2020-09-16 | 山陽特殊製鋼株式会社 | Soft magnetic flat powder and its manufacturing method |
JP6702830B2 (en) * | 2015-09-28 | 2020-06-03 | 住友電気工業株式会社 | Dust core and coil parts |
CN105895301B (en) * | 2016-05-28 | 2017-12-29 | 深圳市固电电子有限公司 | A kind of ferrocart core inductance and preparation method thereof |
JP2021052075A (en) * | 2019-09-25 | 2021-04-01 | 太陽誘電株式会社 | Coil component |
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US5063011A (en) * | 1989-06-12 | 1991-11-05 | Hoeganaes Corporation | Doubly-coated iron particles |
JPH08921B2 (en) * | 1992-06-19 | 1996-01-10 | 株式会社神戸製鋼所 | Pure iron powder for powder metallurgy with excellent compressibility and magnetic properties |
US5595609A (en) * | 1993-04-09 | 1997-01-21 | General Motors Corporation | Annealed polymer-bonded soft magnetic body |
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US6372348B1 (en) * | 1998-11-23 | 2002-04-16 | Hoeganaes Corporation | Annealable insulated metal-based powder particles |
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US7153594B2 (en) * | 2002-12-23 | 2006-12-26 | Höganäs Ab | Iron-based powder |
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2003
- 2003-09-09 SE SE0302427A patent/SE0302427D0/en unknown
-
2004
- 2004-09-08 PL PL04775401T patent/PL1663549T3/en unknown
- 2004-09-08 AT AT04775401T patent/ATE394187T1/en active
- 2004-09-08 BR BRPI0413853-8A patent/BRPI0413853B1/en not_active IP Right Cessation
- 2004-09-08 MX MXPA06002643 patent/MX258741B/en active IP Right Grant
- 2004-09-08 KR KR1020067004853A patent/KR101097896B1/en active IP Right Grant
- 2004-09-08 DE DE602004013606T patent/DE602004013606D1/de active Active
- 2004-09-08 WO PCT/SE2004/001296 patent/WO2005023464A1/en active Application Filing
- 2004-09-08 ZA ZA200601216A patent/ZA200601216B/en unknown
- 2004-09-08 ES ES04775401T patent/ES2305851T3/en active Active
- 2004-09-08 AU AU2004270090A patent/AU2004270090B2/en not_active Ceased
- 2004-09-08 US US10/568,952 patent/US7455905B2/en active Active
- 2004-09-08 CN CNB2004800252488A patent/CN100439012C/en active Active
- 2004-09-08 RU RU2006111507/02A patent/RU2311261C2/en not_active IP Right Cessation
- 2004-09-08 JP JP2006526044A patent/JP4880462B2/en active Active
- 2004-09-08 EP EP04775401A patent/EP1663549B1/en active Active
- 2004-09-08 CA CA2534466A patent/CA2534466C/en active Active
- 2004-09-09 TW TW093127323A patent/TWI289487B/en active
-
2010
- 2010-03-29 JP JP2010075052A patent/JP2010209469A/en not_active Withdrawn
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WO1989004540A1 (en) * | 1987-10-30 | 1989-05-18 | R.S. Ruffini & Associates | Inductor insert compositions and methods |
WO1996030144A1 (en) * | 1995-03-28 | 1996-10-03 | Höganäs Ab | Soft magnetic anisotropic composite materials |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1716946A1 (en) * | 2004-01-30 | 2006-11-02 | Sumitomo Electric Industries, Ltd. | Soft magnetic material and dust core |
EP1716946A4 (en) * | 2004-01-30 | 2008-10-22 | Sumitomo Electric Industries | Soft magnetic material and dust core |
EP2147445A2 (en) * | 2006-12-07 | 2010-01-27 | Höganäs AB | Soft magnetic powder |
EP2147445A4 (en) * | 2006-12-07 | 2011-09-07 | Hoeganaes Ab | Soft magnetic powder |
US8187394B2 (en) | 2006-12-07 | 2012-05-29 | Hoganas Ab | Soft magnetic powder |
JP2015053499A (en) * | 2006-12-07 | 2015-03-19 | ホガナス アクチボラゲット | Soft magnetic powder |
Also Published As
Publication number | Publication date |
---|---|
KR20060121865A (en) | 2006-11-29 |
TWI289487B (en) | 2007-11-11 |
KR101097896B1 (en) | 2011-12-23 |
MXPA06002643A (en) | 2006-06-06 |
EP1663549A1 (en) | 2006-06-07 |
DE602004013606D1 (en) | 2008-06-19 |
RU2006111507A (en) | 2006-08-27 |
AU2004270090A1 (en) | 2005-03-17 |
RU2311261C2 (en) | 2007-11-27 |
MX258741B (en) | 2008-07-14 |
CN1845805A (en) | 2006-10-11 |
PL1663549T3 (en) | 2008-12-31 |
JP2010209469A (en) | 2010-09-24 |
EP1663549B1 (en) | 2008-05-07 |
SE0302427D0 (en) | 2003-09-09 |
CN100439012C (en) | 2008-12-03 |
ZA200601216B (en) | 2007-05-30 |
BRPI0413853B1 (en) | 2015-06-23 |
JP4880462B2 (en) | 2012-02-22 |
US7455905B2 (en) | 2008-11-25 |
US20060214138A1 (en) | 2006-09-28 |
TW200524690A (en) | 2005-08-01 |
AU2004270090B2 (en) | 2007-11-01 |
CA2534466A1 (en) | 2005-03-17 |
BRPI0413853A (en) | 2006-10-24 |
ATE394187T1 (en) | 2008-05-15 |
CA2534466C (en) | 2010-05-04 |
ES2305851T3 (en) | 2008-11-01 |
JP2007505216A (en) | 2007-03-08 |
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