WO2006064794A1 - 鉄基希土類系ナノコンポジット磁石およびその製造方法 - Google Patents
鉄基希土類系ナノコンポジット磁石およびその製造方法 Download PDFInfo
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- WO2006064794A1 WO2006064794A1 PCT/JP2005/022857 JP2005022857W WO2006064794A1 WO 2006064794 A1 WO2006064794 A1 WO 2006064794A1 JP 2005022857 W JP2005022857 W JP 2005022857W WO 2006064794 A1 WO2006064794 A1 WO 2006064794A1
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- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
- B22D11/0622—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by two casting wheels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
- B22D11/0611—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by a single casting wheel, e.g. for casting amorphous metal strips or wires
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- 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
- B22F1/07—Metallic powder characterised by particles having a nanoscale microstructure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y25/00—Nanomagnetism, e.g. magnetoimpedance, anisotropic magnetoresistance, giant magnetoresistance or tunneling magnetoresistance
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/003—Making ferrous alloys making amorphous alloys
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/005—Ferrous alloys, e.g. steel alloys containing rare earths, i.e. Sc, Y, Lanthanides
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/10—Ferrous alloys, e.g. steel alloys containing cobalt
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/14—Ferrous alloys, e.g. steel alloys containing titanium or zirconium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C45/00—Amorphous alloys
- C22C45/02—Amorphous alloys with iron as the major constituent
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- 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
- H01F1/032—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 hard-magnetic materials
- H01F1/04—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 hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
- H01F1/0579—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B with exchange spin coupling between hard and soft nanophases, e.g. nanocomposite spring magnets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
- B22F2009/045—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling by other means than ball or jet milling
- B22F2009/046—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling by other means than ball or jet milling by cutting
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- 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
- H01F1/032—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 hard-magnetic materials
- H01F1/04—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 hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
- H01F1/053—Alloys characterised by their composition containing rare earth metals
- H01F1/055—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5
- H01F1/057—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B
- H01F1/0571—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes
- H01F1/0575—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together
- H01F1/0578—Alloys characterised by their composition containing rare earth metals and magnetic transition metals, e.g. SmCo5 and IIIa elements, e.g. Nd2Fe14B in the form of particles, e.g. rapid quenched powders or ribbon flakes pressed, sintered or bonded together bonded together
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- 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
Definitions
- Iron-based rare earth nanocomposite magnet and manufacturing method thereof Iron-based rare earth nanocomposite magnet and manufacturing method thereof
- the present invention relates to an iron-based rare earth nanocomposite magnet and a method for producing the same.
- the present invention also relates to a rapidly solidified alloy for iron-based rare earth-based nanocomposite magnets and a bonded magnet containing powders of iron-based rare earth-based nanocomposite magnets.
- a hard magnetic phase such as an Nd Fe B phase (hereinafter, sometimes referred to as "2-14-1 phase").
- Nanocomposite permanent magnets have been developed that have a structure in which iron-based borides and soft magnetic phases such as ⁇ -Fe are magnetically coupled.
- Nd in “2-14-1 phase” may be substituted with other rare earth elements, and a part of Fe may be substituted with Co and / or Ni.
- part of B in the 2-14-1 phase may be substituted by C (carbon).
- the coercivity of a Ti-containing nanocomposite magnet mainly composed of iron-based boride as the soft magnetic phase described in Patent Document 1 is about 500 kA / m to 1000 kA / m, which is very high as a nanocomposite magnet.
- the residual magnetic flux density is about 0.9T at the highest.
- Patent Document 2 and Patent Document 3 disclose a rare-earth nanocomposite magnets mainly composed of a Fe. According to this type of nanocomposite magnet, a high remanence of 0.9T or higher A bundle density can be expected.
- Patent Document 1 Japanese Patent No. 3264664
- Patent Document 2 JP-A-8-162312
- Patent Document 3 Japanese Patent Laid-Open No. 10-53844
- Patent Document 2 and Patent Document 3 have a low coercive force of 3 ⁇ 400 kA / m or less and cannot be put to practical use. There is.
- the present invention has been made in order to solve the above-mentioned problems, and an object of the present invention is to provide an iron-based rare earth having magnetic properties of a coercive force of 400 kA / m or more and a residual magnetic flux density of 0.9 T or more. It is to provide a similar nanocomposite magnet.
- Another object of the present invention is to provide a rapidly solidified alloy for the iron-based rare earth nanocomposite magnet, a powder of the iron-based rare earth nanocomposite magnet, and the like. Means for solving the problem
- the iron-based rare earth nanocomposite magnet of the present invention has a composition formula T Q R Ti M HiFe
- the particle diameter is 20 nm or more, and the ferro-Fe phase has a thickness of the R Fe B-type compound phase of 20 nm.
- the R Fe B-type compound phase has an average crystal grain size of 30 nm or more. Above 300 nm and below, the average crystal grain size of the ⁇ -Fe phase is not less than 1 nm and not more than 20 nm.
- the R Fe B type relative to the average crystal grain size of the a-Fe phase
- the ratio of the average crystal grain size of the 2 14 compound phase is 2.0 or more.
- the one Fe phase is a grain boundary of the R Fe B-type compound phase.
- the volume ratio of the Fe phase is 5 as a whole. / 0 or more.
- the rapidly solidified alloy for iron-based rare earth nanocomposite magnets of the present invention has a composition formula T
- QR Ti M (T is Fe, or part of Fe is a group force consisting of Co and Ni. Transition metal element substituted with one or more selected elements.
- Q is selected from the group consisting of B and C.
- At least one element, R is essentially free of La and Ce, one or more rare earth elements, M is Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo , Ag, Hf, Ta, W, Pt, Au, and Pb), and the composition ratios x, y, z, and n are 5 ⁇ ⁇ 10, respectively.
- an R Fe B-type compound phase having an average thickness of 50 / im to 300 / im and an average crystal grain size of 80 nm or less is contained in an amount of 20% by volume or more.
- the standard deviation ⁇ of thickness is 5 ⁇ or less.
- the crystallized layer has at least a free cooling side surface.
- the bonded magnet of the present invention includes the powder of the iron-based rare earth nanocomposite magnet.
- the method for producing an iron-based rare earth nanocomposite magnet of the present invention comprises a composition formula T Q R
- Ti M (T is Fe, or a transition metal element in which part of Fe is substituted with one or more elements selected from the group consisting of Co and Ni, Q is a minimum selected from the group consisting of B and C 1 element, R is one or more rare earth elements substantially free of La and Ce, M is Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag , Hf, Ta, W, Pt, Au, and Pb), and the composition ratios x, y, z, and n are 5 ⁇ ⁇ 10, respectively.
- a molten alloy having a composition satisfying atomic%, 7 ⁇ 10 atomic%, 0.1 ⁇ 2 ⁇ 5 atomic%, and 0 ⁇ n ⁇ 10 atomic%; and R Fe B type compound with an average crystal grain size of 80 nm or less
- the ⁇ -Fe phase is 20 nm or less in thickness of the R Fe B-type compound phase.
- the R Fe B-type compound phase has an average crystal grain size of 30 nm or less.
- the average grain size of the Fe-Fe phase is not less than 1 nm and not more than 20 nm.
- the rapid cooling step cools and solidifies the molten metal of the alloy, and has a mean thickness of 50 ⁇ m to 300 ⁇ m and a standard deviation ⁇ of thickness of 5 ⁇ m or less. Forms a cold solidified alloy.
- the method for producing an iron-based rare earth nanocomposite magnet powder according to the present invention comprises a step of preparing any one of the above rapidly solidified alloys for iron-based rare earth nanocomposite magnets, and powdering the rapidly solidified alloy. Producing a magnetic powder.
- R Fe having an average crystal grain size of 30 nm or more and 300 nm or less is obtained.
- It contains a B-type compound phase and an ⁇ -Fe phase with an average crystal grain size of 1 nm or more and 20 nm or less, and exhibits magnetic properties with a coercive force of 400 kA / m or more and a residual magnetic flux density of 0.9 T or more.
- the molten alloy is rapidly cooled at a lower quenching rate than that of the prior art, while suppressing the precipitation and growth of a_Fe due to the effect of the Ti additive. For this reason, a fine R F with an average crystal grain size of 80 nm or less is obtained without amorphizing the entire rapidly solidified alloy immediately after quenching.
- a rapidly solidified alloy containing 20 vol% or more of the 2 e B-type compound phase can be obtained. like this
- the force that precipitates at the grain boundary (typically the grain boundary triple point) of the Fe B-type compound phase.
- R Fe with a diameter between lnm and 20nm and an average crystal grain size between 30nm and 300nm
- FIG. 1 (a) to (d) are diagrams schematically showing a structure of a nanocomposite magnet.
- FIG. 2 (a) and (b) are diagrams showing a rapid cooling device (melt spinning device).
- FIG. 3 is a cross-sectional TEM (transmission electron microscope) photograph showing the structure of an example of the present invention.
- a molten alloy expressed by the composition formula T Q R Ti M is formed.
- T is Fe, or a transition metal element in which part of Fe is substituted with one or more elements selected from the group consisting of Co and Ni, Q is selected from the group consisting of B and C at least One element, R is essentially free of La and Ce, one or more rare earth elements, M is Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, One or more metal elements selected from the group consisting of Ag, Hf, Ta, W, Pt, Au, and Pb.
- composition ratios x, y, z and n in the above composition formula are 5 ⁇ ⁇ 10 atomic%, 7 ⁇ ⁇ 10 atomic%, 0.1 ⁇ 2 ⁇ 5 atomic%, 0 ⁇ ⁇ 10 atomic%, respectively. Is satisfied.
- the molten alloy having the above composition is cooled and solidified to produce a rapidly solidified alloy containing 20% by volume or more of an R Fe B type compound phase having an average crystal grain size of 80 nm or less (quenching process). ).
- the molten alloy is as high as possible.
- the molten alloy is cooled at a relatively low quenching rate, and R Fe B having an average crystal grain size of 80 nm or less is cooled at a rapid cooling rate.
- the average grain size is larger than that of the R Fe B type compound phase.
- Kinahi _Fe phase is dominant, and there is more _Fe phase in volume ratio than R Fe B type compound phase
- the thickness deviation of the rapidly solidified alloy ⁇ is set to 5 ⁇ or less, and a rapidly cooled alloy having a small variation in thickness is obtained, whereby the R Fe B type compound phase and the amorphous phase are obtained.
- a fine metal structure in which is uniformly mixed can be obtained.
- the rapid cooling rate by the cooling roll varies depending on the thickness of the rapidly solidified alloy to be formed.
- the standard deviation ⁇ of the thickness of the rapidly solidified alloy immediately after quenching is set to 5 It is necessary to prepare rapid cooling conditions so that it is less than ⁇ m.
- the melt quenching method using a tundish having a tubular hole described in JP-A-2004-122230 can be suitably used.
- a cooling roll having a smooth surface When performing these quenching methods, it is preferable to use a cooling roll having a smooth surface and to perform quenching in a reduced-pressure atmosphere in order to suppress entrainment of atmospheric gas into the roll.
- the rapidly solidified alloy thus obtained is then subjected to a heat treatment to crystallize the amorphous phase in the rapidly solidified alloy, and finally a nanocomposite magnet having high magnetic properties can be obtained.
- an R Fe B-type compound phase having an average crystal grain size of 30 nm to 300 nm and an average crystal grain size of 1 nm or less.
- Fine one Fe phase exists at the grain boundary triple point of Fe B type compound phase.
- FIGS. 1 (a) to (d) schematically shows the microstructure of the rapidly solidified alloy, and each of the rectangular regions located on the right side is heated. The microstructure of the nanocomposite magnet after processing is shown.
- FIGS. L (a) to (d) are respectively a nanocomposite magnet according to the present invention, a conventional ⁇ -Fe / RFeB-based nanocomposite magnet, and a conventional a-Fe / RFeB-based nanocomposite magnet.
- fine Hi-Fe may be formed. This is because the growth rate of the Fe-Fe phase is suppressed during the subsequent heat treatment due to the effect of the Ti addition force, and after the heat treatment, the grain boundary triple point of the preferentially grown R Fe B-type compound phase
- the fine Hiichi Fe phase (in the figure,
- the rapidly solidified alloy is in a substantially complete amorphous state. After heat treatment, approximately the same size
- a refined tissue is produced.
- the R Fe B-type compound phase is formed inside, but the final structure is the individual R Fe
- the Hi-FeZR Fe B-based nanocomposite magnet the Hi-Fe phase is combined with the R Fe B-type compound.
- the Fe-Fe phase and the R Fe B-type compound phase have approximately the same average grain size.
- the nanocomposite magnet of the present invention has a unique structure in which minute ⁇ -Fe phases are discretely dispersed at the grain boundaries of a relatively large R Fe B-type compound phase.
- the raw material alloy is manufactured using the quenching apparatus shown in FIG.
- the alloy manufacturing process is performed in an inert gas atmosphere in order to prevent oxidation of the raw material alloy containing rare earth elements R and Fe, which are easily oxidized.
- the inert gas a rare gas such as helium or argon or nitrogen can be used.
- the apparatus shown in FIG. 2 includes a raw material alloy melting chamber 1 and a quenching chamber 2 that can maintain a vacuum or an inert gas atmosphere and adjust the pressure.
- Fig. 2 (a) is an overall configuration diagram
- Fig. 2 (b) is a partially enlarged view.
- the melting chamber 1 includes a melting furnace 3 for melting the raw material 20 blended so as to have a desired magnet alloy composition at a high temperature, and a tapping nozzle 5 at the bottom.
- a melting furnace 3 for melting the raw material 20 blended so as to have a desired magnet alloy composition at a high temperature
- tapping nozzle 5 at the bottom.
- the hot water storage container 4 stores a molten alloy 21 of the raw material alloy and has a heating device (not shown) that can maintain the temperature of the hot water at a predetermined level.
- the quenching chamber 2 is provided with a rotary cooling roll 7 for rapidly cooling and solidifying the molten metal 21 discharged from the hot water nozzle 5.
- the atmosphere in the melting chamber 1 and the quenching chamber 2 and its pressure are controlled within a predetermined range.
- atmospheric gas supply ports lb, 2b, and 8b and gas exhaust ports la, 2a, and 8a are provided at appropriate locations in the apparatus.
- the gas exhaust port 2a is connected to a pump in order to control the absolute pressure in the quenching chamber 2 within a range of 30 kPa to normal pressure (atmospheric pressure).
- the melting furnace 3 is tiltable, and the molten metal 21 is appropriately poured into the hot water storage container 4 through the funnel 6.
- the molten metal 21 is heated in the hot water storage container 4 by a heating device (not shown).
- the hot water discharge nozzle 5 of the hot water storage container 4 is disposed in the partition wall between the melting chamber 1 and the quenching chamber 2, and causes the molten metal 21 in the hot water storage container 4 to flow down to the surface of the cooling roll 7 positioned below.
- the orifice diameter of the hot water nozzle 5 is, for example, 0.5 to 2 Omm.
- the cooling roll 7 may be formed of A1 alloy, copper alloy, carbon steel, brass, W, Mo, bronze in terms of thermal conductivity. However, from the viewpoint of mechanical strength and economy, it is preferable to form Cu, Fe, or an alloy containing Cu or Fe. If the chill roll is made of a material other than Cu or Fe, the peelability of the quenched alloy from the chill roll deteriorates, so the quenched alloy may be wound around the roll.
- the diameter of the cooling roll 7 is, for example, 300 to 50 Omm.
- the water cooling capacity of the water cooling device provided in the cooling roll 7 is calculated and adjusted according to the solidification latent heat per unit time and the amount of tapping water.
- a total of 10 kg of raw material alloy can be rapidly cooled and solidified in 10 to 20 minutes.
- the quenched alloy thus formed becomes, for example, an alloy ribbon (alloy ribbon) 22 having a thickness of 10 to 300 zm and a width of 2 to 3 mm.
- a raw alloy melt 21 expressed by the following composition formula is prepared and stored in the hot water storage container 4 of the melting chamber 1 in FIG.
- Alloy composition represented by the composition formula T Q R Ti M, and the composition ratios x, y, z and n are
- T is Fe, or a transition metal element in which part of Fe is substituted with one or more elements selected from the group consisting of Co and Ni, and Q is at least selected from the group consisting of B and C
- R is essentially free of La and Ce, one or more rare earth elements
- M is Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, One or more metal elements selected from the group consisting of Mo, Ag, Hf, Ta, W, Pt, Au, and Pb.
- the molten metal 21 is discharged from the hot water discharge nozzle 5 onto the cooling roll 7 in a reduced pressure Ar atmosphere, rapidly cooled by contact with the cooling roll 7 and solidified.
- the rapid solidification method it is necessary to use a method capable of controlling the cooling speed with high accuracy.
- the cooling rate it is preferable to set the cooling rate to 1 ⁇ 10 4 to 1 ⁇ 10 6 ° C / sec when the molten metal 21 is cooled and solidified. 3 ⁇ 10 4 to 1 ⁇ 10 6 ° C 1 ⁇ 10 5 to 1 ⁇ 10 6 ° CZ seconds is more preferable.
- the time during which the molten alloy 21 is cooled by the cooling roll 7 corresponds to the time from when the alloy comes into contact with the outer peripheral surface of the rotating cooling roll 7 until it leaves, during which the temperature of the alloy decreases. Then, it becomes a supercooled liquid state. Thereafter, the supercooled alloy leaves the cooling roll 7 and flies in an inert atmosphere.
- the alloy While the alloy is in the form of a ribbon, its temperature is further reduced as a result of the heat deprived of the ambient gas.
- the atmospheric gas pressure is set within a range from 30 kPa to normal pressure, so the heat removal effect by the atmospheric gas is strengthened, and Nd Fe B-type compounds are precipitated and grown uniformly and finely in the alloy. be able to.
- Fe will preferentially precipitate and grow in the quenched alloy that has undergone the cooling process as described above. Since Fe_Fe in the obtained magnet is coarsened, the magnet characteristics are deteriorated.
- the roll surface speed is adjusted within the range of 10 mZ seconds to 30 mZ seconds (preferably 14 to 25 m / sec, more preferably 18 to 22 m / sec) and By increasing the atmospheric gas pressure to 30 kPa or higher in order to enhance the secondary cooling effect, quenching containing 20% by volume or more of a fine R Fe B-type compound phase with an average particle size of 80 nm or less
- An alloy is made. Such a crystal layer is formed substantially uniformly on the free cooling surface side of the rapidly solidified alloy ribbon to form a crystallized layer.
- a thin crystallized layer can also be formed on the extreme surface layer on the cooling roll side of the rapidly solidified alloy ribbon.
- the intermediate region sandwiched between these crystallized layers is in an amorphous state or nearly amorphous state.
- the heat treatment is performed in an argon atmosphere.
- the heating rate is 5 ° C / second to 20 ° C / second, and the temperature is maintained at 550 ° C or higher and 850 ° C or lower for 30 seconds or longer and 20 minutes or shorter, and then cooled to room temperature.
- the fine Nd Fe B-type crystal phase is already 20% by volume or more of the whole at the start of the heat treatment.
- the nanocomposite magnet obtained after heat treatment has a structural structure in which mainly Fe is present at the grain boundaries of the Nd Fe B-type crystal phase. Has a structure.
- the existence ratio of a-Fe is considered to be 5% by volume or more of the whole, and the residual magnetic flux density of the whole magnet is improved.
- the heat treatment temperature is lower than 550 ° C, a large amount of amorphous phase remains even after the heat treatment, and the coercive force may not reach a sufficient level depending on the rapid cooling conditions.
- the heat treatment temperature exceeds 850 ° C, the residual magnetic flux density B, where the grain growth of each constituent phase is significant, decreases, and the squareness of the demagnetization curve deteriorates. Therefore, the heat treatment temperature is preferably 550 ° C. or higher and 850 ° C. or lower, but the more preferable heat treatment temperature range is 570 ° C. or higher and 820 ° C. or lower.
- the heat treatment atmosphere is preferably an inert gas atmosphere in order to prevent oxidation of the alloy.
- the heat treatment may be performed in a vacuum of 0. lkPa or less.
- metastable phases such as Fe B phase, Fe B, and R Fe B phase are included, it is good. In that case
- the R Fe B phase disappears and is equivalent to or saturated with the saturation magnetization of the R Fe B phase.
- Iron-based borides that exhibit higher saturation magnetization eg Fe B
- the average crystal grain size of the R Fe B-type compound phase after heat treatment is the single domain crystal grain size.
- the viewpoint power for improving the coercive force and the squareness of the demagnetization curve is preferably 30 nm or more and 150 nm or less, more preferably 30 nm or more and lOOnm or less.
- the average grain size of the a-Fe phase exceeds 20 nm, the exchange interaction between the constituent phases is weakened, and ⁇ having a multi-domain structure instead of a single domain
- the a-Fe phase average crystal grain size is preferably 1 nm or more and 20 nm or less.
- the average crystal grain size of the R Fe B type compound phase is the average crystal of the _Fe phase.
- the ratio of the former to the latter, which is larger than the particle size, is 1.5 or more. This ratio is preferably 2.0 or more.
- the ribbon of the quenched alloy may be roughly cut or pulverized. After heat treatment, the obtained magnet is pulverized to produce magnet powder (magnetic powder).
- magnet powder magnetic powder
- the iron-based rare earth alloy magnetic powder is mixed with an epoxy resin or a nylon resin and formed into a desired shape.
- the nanocomposite magnetic powder may be mixed with other kinds of magnetic powder, for example, Sm—Fe—N-based magnetic powder or hard ferrite magnetic powder.
- composition of the iron-based rare earth nanocomposite magnet according to the present invention is T Q
- T is selected from the group force consisting of Fe or Co and Ni n
- Transition metal element including at least one element selected from the group consisting of Fe, Q is at least one element selected from the group consisting of B and C, R is L that is substantially free of La and Ce, one or more elements
- the rare earth element, M was selected from the group consisting of Al, Si, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au, and Pb One or more metal elements.
- the composition ratios x, y, z, and n are 5 ⁇ ⁇ 10 atomic%, 7 ⁇ y ⁇ 10 atomic% (preferably 8 ⁇ y ⁇ 10 atomic%), and 0 ⁇ l ⁇ z ⁇ 5 atoms, respectively. % (Preferably 0.5 ⁇ z ⁇ 4 atomic%) and 0 ⁇ n ⁇ 10 atomic%.
- Q is composed entirely of B (boron) or a combination of B and C (carbon).
- the atomic ratio of C to the total amount of Q is preferably 0.5 or less.
- composition ratio X of Q When Ti is not added, when the composition ratio X of Q is less than 7 atomic%, the amorphous formation ability is greatly reduced, so a uniform fine metal structure is not obtained, and a residual magnetic flux density of 0.9 T or more is obtained. Br cannot be obtained.
- the lower limit of the composition ratio X of Q is 5 atomic% because the amorphous forming ability is improved by the Ti additive.
- the composition ratio X of Q exceeds 10 atomic%, the abundance ratio of _Fe having the highest saturation magnetization in the constituent phases decreases, and instead of Fe B, Fe B, and Fe B as the soft magnetic phase. A residual magnetic flux density B of 0.9 T or more was obtained.
- the composition ratio X of Q is preferably set so as to be 5 atomic% or more and 10 atomic% or less.
- a more preferable range of the composition ratio X is 5.5 atomic% or more and 9.5 atomic% or less, and a further preferable range of the composition ratio X is 5.5 atomic% or more and 9.0 atomic% or less.
- a more preferable upper limit of the composition ratio X is 8 atomic%. Note that even if a part of B (at atomic ratio up to 50 / o) is replaced with carbon (C), it does not affect the magnetic properties and metal structure, so it is acceptable. Is done.
- R is one or more elements selected from the group of rare earth elements (including Y).
- La or Ce When La or Ce is present, the coercive force and the squareness deteriorate, so that it is preferable that La and Ce are not substantially contained.
- a trace amount of La or Ce 0.5 atomic% or less exists as an unavoidable impurity, there is no problem in terms of magnetic properties. Therefore, when it contains 0.5 atomic% or less of La and Ce, it can be said that La and Ce are not substantially contained.
- R preferably contains Pr or Nd as an essential element.
- a part of the essential element may be substituted with Dy and / or Tb.
- the R composition ratio y is less than 7 atomic% of the total, the compound phase having the R Fe B type crystal structure necessary for the expression of the coercive force is formed.
- the composition ratio y of the rare earth element R is preferably adjusted to a range of 7 atomic% to 10 atomic%, for example, 7.5 atomic% to 9.8 atomic%.
- a more preferable range of R is 8 atom% or more and 9.8 atom% or less, and a most preferable range of R is 8.2 atom% or more and 9.7 atom% or less.
- Ti is an indispensable element for obtaining the above-described effect, and includes coercive force H and residual magnetic flux cj.
- the Ti composition ratio z is preferably in the range of 0.1 atomic% to 5 atomic%. More preferably, the lower limit of the z range is 0.5 atomic percent, and even more preferably, the lower limit of the z range is 1 atomic percent. Also, more preferred, the upper limit of z range is 4 atomic%.
- the transition metal T mainly composed of Fe occupies the residual content of the above-mentioned elements. However, even if a part of Fe is replaced with one or two transition metal elements of Co and Ni, the desired hard magnetism is obtained. The characteristics can be obtained. If the substitution amount of Co or Ni for Fe exceeds 50%, a high residual magnetic flux density B of 0.5T or more cannot be obtained. Therefore, the substitution amount is 0% or more and 50% or less It is preferable to limit to the range. Replacing part of Fe with Co improves the squareness of the demagnetization curve and increases the Curie temperature of the R Fe B phase.
- Thermal properties are improved.
- the addition of Co reduces the viscosity of the molten alloy when the molten alloy is rapidly cooled, so that a stable liquid quenching can be maintained.
- a preferable range of the amount of Fe substitution by Co is 0.5% or more and 15% or less.
- the addition of such elements can improve the magnetic properties and expand the optimum heat treatment temperature range.
- the M composition ratio n is limited to the range of 0 atomic% to 10 atomic%.
- a preferable range of the composition ratio n of M is 0.1 atomic% or more and 5 atomic% or less.
- the raw material in the nozzle was melted by high-frequency heating in an Ar atmosphere, and the temperature of the resulting molten alloy was 1400. After reaching C, the inside of the nozzle was pressurized with 30 kPa of argon gas, and the molten alloy was ejected from the orifice at the bottom of the nozzle to the surface of the cooling roll.
- the cooling roll rotates at high speed while the inside is cooled so that the temperature of the outer peripheral surface thereof is maintained at about room temperature. For this reason, the molten alloy ejected from the orifice comes into contact with the circumferential surface of the roll and is deprived of heat while being blown away in the circumferential speed direction.
- the peripheral speed Vs of the cooling roll was set to 20 m / sec.
- the obtained quenched alloy has a quenched alloy structure in which amorphous, Nd Fe B phase and crystal phase presumed to be ⁇ -Fe are mixed.
- the obtained alloy ribbon was cut to a length of about 20 mm, and then in an Ar atmosphere, 630 to
- a crystallization heat treatment was carried out at 700 ° C for 10 minutes.
- FIG. 3 is a TEM (transmission electron microscope) photograph showing a cross section of the sample of Example 19. From this photo, it is observed that the Fe-Fe phase is present in an amount of 5% by volume or more.
- Table 2 shows the magnetic properties of the quenched alloy ribbon after crystallization heat treatment at room temperature, measured using a vibrating magnetometer.
- the obtained alloy ribbon was cut to a length of about 20 mm, and then subjected to a crystallization heat treatment for 10 minutes at a temperature of 630 to 700 ° C in an Ar atmosphere.
- Example 1 1 0 9 bal. 8 5.5 0.5 2 0
- Example 27 7 0 bal. 0 7 0 0 0
- the fine metal was a mixture of Nd Fe B phase and a- Fe phase with an average crystal grain size of 30 nm to 100 nm.
- Table 2 shows the magnetic properties of the quenched alloy ribbon after crystallization heat treatment at room temperature.
- an iron-based rare earth nanocomposite magnet having a magnetic characteristic of a coercive force of 400 kAZm or more and a residual magnetic flux density of 0.9 T or more is provided, and the residual magnetic flux density is high as in a small motor or sensor. It is suitably used for electronic devices that require magnets.
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- Metallurgy (AREA)
- Crystallography & Structural Chemistry (AREA)
- Nanotechnology (AREA)
- Inorganic Chemistry (AREA)
- Composite Materials (AREA)
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Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP05816736.2A EP1826782B1 (en) | 2004-12-16 | 2005-12-13 | Iron base rare earth nano-composite magnet and method for production thereof |
US10/596,880 US7842140B2 (en) | 2004-12-16 | 2005-12-13 | Iron-based rare-earth nanocomposite magnet and method for producing the magnet |
JP2006519681A JP4169074B2 (ja) | 2004-12-16 | 2005-12-13 | 鉄基希土類系ナノコンポジット磁石およびその製造方法 |
KR1020067010044A KR101311058B1 (ko) | 2004-12-16 | 2005-12-13 | 철기재의 희토류계 나노컴포지트 자석 및 그 제조방법 |
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JP2004364544 | 2004-12-16 | ||
JP2004-364544 | 2004-12-16 |
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WO2006064794A1 true WO2006064794A1 (ja) | 2006-06-22 |
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PCT/JP2005/022857 WO2006064794A1 (ja) | 2004-12-16 | 2005-12-13 | 鉄基希土類系ナノコンポジット磁石およびその製造方法 |
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US (1) | US7842140B2 (ja) |
EP (1) | EP1826782B1 (ja) |
JP (2) | JP4169074B2 (ja) |
KR (1) | KR101311058B1 (ja) |
CN (1) | CN100590757C (ja) |
WO (1) | WO2006064794A1 (ja) |
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JP2008078614A (ja) * | 2006-08-25 | 2008-04-03 | Hitachi Metals Ltd | 等方性鉄基希土類合金磁石の製造方法 |
JP2008192903A (ja) * | 2007-02-06 | 2008-08-21 | Hitachi Metals Ltd | 鉄基希土類合金磁石 |
JP2010199230A (ja) * | 2009-02-24 | 2010-09-09 | Hitachi Metals Ltd | 鉄基希土類系ナノコンポジット磁石およびその製造方法 |
US20150093501A1 (en) * | 2009-07-01 | 2015-04-02 | Shin-Etsu Chemical Co., Ltd. | Rare earth magnet and its preparation |
US10160037B2 (en) * | 2009-07-01 | 2018-12-25 | Shin-Etsu Chemical Co., Ltd. | Rare earth magnet and its preparation |
US10614952B2 (en) | 2011-05-02 | 2020-04-07 | Shin-Etsu Chemical Co., Ltd. | Rare earth permanent magnets and their preparation |
US11482377B2 (en) | 2011-05-02 | 2022-10-25 | Shin-Etsu Chemical Co., Ltd. | Rare earth permanent magnets and their preparation |
US11791093B2 (en) | 2011-05-02 | 2023-10-17 | Shin-Etsu Chemical Co., Ltd. | Rare earth permanent magnets and their preparation |
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Also Published As
Publication number | Publication date |
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KR20070100095A (ko) | 2007-10-10 |
US20090223606A1 (en) | 2009-09-10 |
EP1826782A1 (en) | 2007-08-29 |
JP4858497B2 (ja) | 2012-01-18 |
JP2009013498A (ja) | 2009-01-22 |
EP1826782B1 (en) | 2016-03-02 |
KR101311058B1 (ko) | 2013-09-24 |
JPWO2006064794A1 (ja) | 2008-06-12 |
CN1906713A (zh) | 2007-01-31 |
JP4169074B2 (ja) | 2008-10-22 |
US7842140B2 (en) | 2010-11-30 |
EP1826782A4 (en) | 2010-05-05 |
CN100590757C (zh) | 2010-02-17 |
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